Dodge - Caravan Fwd - Workshop Manual - 1999 - 1999

Factory Workshop Manual Make Dodge Model Caravan Fwd Engine and year V6-3.8L VIN L (1999) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 7 Keyless Entry Module: Adjustments The content of this article reflects the changes called out by TSB 26-09-99. PROGRAMMING RKE MODULE 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and was successful. 7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify that the RKE module will no longer accept additional Vehicle Access Code(s). 9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will require programming. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 8 Keyless Entry Module: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws holding RKE module to instrument panel. RKE Module 4. Disconnect wire connector from RKE module. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 13 Keyless Entry Module: Adjustments The content of this article reflects the changes called out by TSB 26-09-99. PROGRAMMING RKE MODULE 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and was successful. 7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify that the RKE module will no longer accept additional Vehicle Access Code(s). 9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will require programming. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 14 Keyless Entry Module: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws holding RKE module to instrument panel. RKE Module 4. Disconnect wire connector from RKE module. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 18 Power Door Lock Relay: Diagrams Junction Block Door Lock Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 19 Door Unlock Relay Driver Door Unlock Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range NO: 08-44-98 GROUP: Electrical DATE: Dec. 11, 1998 SUBJECT: Memory Power Seat Travel Range MODELS: 1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand Cherokee 1996-1998 (ZG) Grand Cherokee (International Market) DISCUSSION: The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motor end, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, no change in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not run into a stall condition (end of travel). The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when something is stuck under or behind the seat that causes the seat to stop moving). These soft stops can prevent the seat from being able to have memory positions set over the full range of travel. Also, positions that were previously programmed to locations beyond an updated soft stop limit will not be recalled as they are "out of range." When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat operation. There are two potential reasons for intermittent memory functioning of the seats. The first possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in the seat's path or a person shifting their body while a power seat motor is in operation.) The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can be caused by a poor connection at pin 23 of the P34 connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locks out" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for fully seated and clean contacts. To check and reset the soft stop limits in memory, use the control switches on the side of the seat to move the seat in one direction to the end of travel, then energize the seat again in the same direction until it stops and for three additional seconds after it stops. The amount that the seat moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat this procedure for each of the directions of movement (one at a time). NOTE: IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE MANUAL). POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation SYSTEM OPERATION The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules are used in the vehicle, one for each front seat. The HSCM for each seat is installed on front portion of each cushion pan. The wire harness connector is secured by an integral clip to the inside surface of the outboard seat cushion frame. Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery feed, and a ground. The only HSCM output is the feed for the seat heating elements. The HSCM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 27 Seat Heater Control Module: Testing and Inspection Before testing the heated seat control module, test the heated seat switch, the heated seat elements, and the heated seat sensor as described. If testing of the heated seat switch, elements, and sensor reveals no problems, proceed as follows. 1. Replace the heated seat control module with a known good unit and test the operation of the heated seats. If OK, discard the faulty heated seat control module. If not OK, go to Step 2. 2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat sensor to the heated seat control module. Repair any short or open circuits as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 28 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5. Remove module from seat cushion pan. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES The ABS system fuse and the ABS pump/motor fuse are located in the Power Distribution Center (PDC). Refer to the sticker on the inside of the PDC cover for the location of these fuses. The PDC is located on the driver's side of the engine compartment. The fuse for the amber ABS warning lamp is located in the fuse junction block under the instrument panel. If the vehicle is equipped with traction control, the fuse for the traction control switch is located in the fuse junction block under the instrument panel. ABS RELAYS Two relays are used to control the antilock brake system. The two relays are the pump/motor relay and the system relay. The pump/motor relay and the system relay are located in the CAB. If either the pump/motor relay or the system relay is diagnosed as not functioning properly, the CAB must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications To HCU Mounting Bolts ....................................................................................................................... .................................................. 2 Nm (17 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 36 Controller Antilock Brake (CAB) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 37 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 38 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the ABS system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the CCD bus. The primary functions of the (CAB) are to: 1. monitor the antilock brake system for proper operation. 2. detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. 3. control fluid modulation to the wheel brakes while the system is in an ABS mode or the traction control system is activated. 4. store diagnostic information. 5. provide communication to the DRB scan tool while in diagnostic mode. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn on the amber ABS warning lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning lamp is turned on and the fault Diagnostic Trouble Code (DTC) is then stored in a diagnostic program memory. These DTCs will remain in the CAB memory even after the ignition has been turned off. The DTCs can be read and cleared from the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 255 key cycles of vehicle operation or 3,600 miles, whichever comes first. CONTROLLER ANTILOCK BRAKE INPUTS - wheel speed sensors (four) - stop lamp switch - ignition switch - system relay voltage - ground. - traction control lamp (if equipped) - diagnostic communication (CCD) CONTROLLER ANTILOCK BRAKE OUTPUTS - body controller communication - amber ABS warning lamp actuation - traction control lamp (if equipped) - diagnostic communication (CCD) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions Radiator Cooling Fan Motor Relay: Technical Service Bulletins Cooling System - Cooling Fan Relay Revisions NUMBER: 26-10-99B GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the cooling fan relay information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 44 7-1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 45 7-12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 46 7-25 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 47 7-25A Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 48 7-25B Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 49 14-49 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 50 Radiator Cooling Fan Motor Relay: Locations Engine Compartment Connections - Early Build Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 51 Engine Compartment Connections - Late Build Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 52 Fan Control Module The SSFR (Solid State Fan Relay) is located on the left front inner frame just behind the radiator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 55 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 57 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 58 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 60 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 63 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 66 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 68 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Radiator Cooling Fan Motor Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 71 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 72 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 73 A/C & Heater -- Sheet 8w-42-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 74 Radiator Cooling Fan Motor Relay: Description and Operation SOLID STATE FAN RELAY-PCM OUTPUT The radiator fan runs at a variable speed depending on coolant temperature and A/C system pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR). A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR. Depending upon the amount of pulse on time, the SSFR puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 102 °C (215 °F) the PCM grounds the SSFR relay. If engine coolant reaches 207 °C (225 °F) the PCM grounds the high speed ground relay and high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and high speed ground relay when coolant temperature drops to approximately 101 °C (214 °F). When coolant temperature drops to 101 °C (214 ° F) the fan operates at low speed. The PCM de-energizes the low speed relay when coolant temperature drops to approximately 93 °C (199 °F). Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan operates at low speed. Fan Control Module The SSFR relay is located on the left front inner frame just behind the radiator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations Blower Motor Relay: Component Locations Power Distribution Center -- Sheet 8w-10-2 Rear Blower Relay Rear Blower Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 80 This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 81 Blower Motor Relay: Connector Locations Power Distribution Center Front Blower Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay Blower Motor Relay: Description and Operation Front Blower Motor Relay Circuit Operation Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1. The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power Distribution Center (PDC). The coil side of the relay is energized when the ignition switch is in the RUN position only. Power for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the relay Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit A22. Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl panel. Ground for the blower motor is controlled through the blower motor resistor and the blower motor switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay > Page 84 Blower Motor Relay: Description and Operation Rear Blower Relay Circuit Operation Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear blower motor passes through the temperature sensor and one or more resistors, depending on speed selection. Two switches operate the rear blower motor by supplying ground; the front control switch and the rear control switch. The front control switch must be in the ON position for the rear control switch to operate the rear blower motor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 89 Power Distribution Center -- Sheet 8w-10-2 The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment next to the battery. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 90 Compressor Clutch Relay: Connector Locations Power Distribution Center A/C Compressor Clutch Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 91 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT The PCM operates the air conditioning clutch relay ground circuit, The radiator fan control module supplies battery power to the solenoid side of the relay. The air conditioning clutch relay will not energize unless the radiator fan control module energizes. The radiator control module energizes when the air conditioning or defrost switch is put in the ON position and the low pressure switch, combination valve, and high pressure switch close. With the engine operating, the PCM cycles the air conditioning clutch on and off when the A/C switch closes with the blower motor switch in the On position. When the PCM senses low idle speeds or wide-open-throttle through the throttle position sensor, it de-energizes the A/C clutch relay. The relay contacts open, preventing air conditioning clutch engagement. The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment next to the battery. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations Cigarette Lighter Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations > Page 96 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations > Page 97 Cigarette Lighter Relay: Diagrams Power Distribution Center Cigar Lighter/Accessory Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 102 Courtesy Lamp Relay: Diagrams Junction Block Courtesy Lamp Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation SYSTEM OPERATION Combination Flasher / Daytime Running Lamps (DRL) Module Junction Block Terminal Pins The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions, and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker, refer to Instrument Panel and Systems. The combination flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of 300 mA., and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground that could draw a maximum of 600 mA. through the multi-function switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 106 Daytime Running Lamp Control Unit: Testing and Inspection Electronic Combination Flasher Circuit Electronic Combination Flasher With DRL Circuit The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/ DRL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 107 Junction Block Terminal Call-Out Junction Block Terminal Call-Out With DRL The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: - Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 108 Combination Flasher Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 109 Combination Flasher Diagnosis (Part 2 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 110 Combination Flasher Diagnosis With DRL (Part 1 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 111 Combination Flasher Diagnosis With DRL (Part 2 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 112 Combination Flasher Diagnosis With DRL (Part 3 Of 3) For diagnostic test procedures, refer to Combination Flasher Diagnosis tables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Technical Service Bulletins > Recalls for Headlamp Control Module: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: Recalls Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Control Module: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 132 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 133 Headlamp Relay: Diagrams Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 134 Power Distribution Center -- Sheet 8w-10-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Diagrams High Beam Relay: Diagrams Power Distribution Center High Beam Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 141 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 142 Horn Relay: Diagrams Power Distribution Center Horn Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 143 Horn Relay: Testing and Inspection 1. Remove horn relay. Horn Relay 2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance. If resistance not OK, replace relay 3. Test for continuity between ground and terminal 85 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary, refer to Passive Restraints for Driver's Airbag Module Replacement. 4. Using voltmeter, test voltage at: a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM. c. If incorrect voltage repair as necessary. 5. Insert a jumper wire between terminal 30 and 87 of the power distribution center. a. If horn sounds replace relay b. If the horn does not sound, install horn relay and refer to Horn Test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams Low Beam Relay: Diagrams Power Distribution Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams > Page 147 Low Beam Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 151 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 152 Parking Lamp Relay: Diagrams Power Distribution Center Park Lamp Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions NUMBER: 26-12-99G GROUP: Miscellaneous DATE: December, 1999 THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the wiring schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 159 8W-44-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 160 8W-44-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 161 8W-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 162 8W-50-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 163 8W-50-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 164 8W-50-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 165 8W-80-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 166 8W-90-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 167 8W-90-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 168 Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 169 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 170 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 171 Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set NO: 18-25-98 GROUP: Vehicle Performance DATE: Aug. 14, 1998 SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code MODELS: 1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE. DISCUSSION: During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous "EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the ignition to the ON position and determine if each PRNDL indicator in the instrument cluster becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not necessary to replace the BCM. NOTE: CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL FAILURE IN THE PRNDL SYSTEM. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 172 Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 175 Junction Block, Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 178 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 181 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 182 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 183 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 184 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 185 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 186 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 187 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 188 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 189 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 190 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 193 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 194 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 195 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 196 Body Control Module: Connector Views Body Control Module C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 197 Body Control Module C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 198 Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 199 Body Control Module Interconnect Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 200 Body Control Module: Electrical Diagrams BCM Block Diagram Wiring Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 201 Body Control Module -- Sheet 8w-45-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 202 Body Control Module -- Sheet 8w-45-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 203 Body Control Module -- Sheet 8w-45-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 204 Body Control Module -- Sheet 8w-45-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 205 Body Control Module -- Sheet 8w-45-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 206 Body Control Module -- Sheet 8w-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Body Control Module -- Sheet 8w-45-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 208 Body Control Module -- Sheet 8w-45-9 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 209 Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 Body Control Module: Description and Operation Part 1 of 3 INTRODUCTION Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. This information will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not come on at all - warning lamp stays on BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: automatic door locks - battery protection - CCD radio - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 212 - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar, ignition, RKE actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as described above. Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and glove box closed). Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened, The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 213 Body Control Module: Description and Operation Part 2 of 3 COMPASS/MINI-TRIP COMPUTER The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. See the service procedure. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Compass Magnetic Variance Zones Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the following zone map provided. The number shown for your area is the variance number for your area. 1. Set the compass/mini-trip console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation, NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS. MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb check is performed. This consists of activating all CCD controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 214 as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Programming an RKE Transmitter Customer Programming Method NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED. 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds. While still holding the unlock button, press the panic button, then release both buttons. The BCM will acknowledge that it has grounded the RKE module program enable wire by sounding a single chime tone. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition off. DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in Programming Mode" does not appear, exit and select "Program RKE" again. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, press "Back Page". RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 215 Body Control Module: Description and Operation Part 3 of 3 VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE COMMUNICATIONS. Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system Will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 216 System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all door are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Test - NOTE: System self-test can be entered only with the DRB. NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. WIPER SYSTEM Front The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned OFF the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. DRB III (R) ERROR MESSAGES Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User- Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 217 DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition WARNINGS Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light GLOSSARY OF ACRONYMS ACM Airbag Control Module AECM Airbag Electronic Control Module (type of ACM) ASDM Airbag System Diagnostic Module (type of ACM) BCM body control module CAB controller antilock brake CCD Chrysler Collision Detection (vehicle communications bus) CMTC Compass/Mini-Trip Computer (module) DLC data link connector (previously called "engine diagnostic connector") DR driver HVAC heater, ventilation, air condition MET metric MIC mechanical instrument cluster MUX multiplexed ODO odometer PASS passenger PCM powertrain control module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 218 PDC powertrain distribution center PTC positive temperature coefficient RKE remote keyless entry TCM transmission control module VF vacuum fluorescent display VTSS vehicle theft security system Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures AM/FM Switch Inoperative SYMPTOM * AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Joystick Inoperative SYMPTOM * BALANCE JOYSTICK INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Cassette Error SYMPTOM CASSETTE ERROR POSSIBLE CAUSES - Cassette Error / Replace radio CD Eject Switch Inoperative SYMPTOM * CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Error SYMPTOM CD ERROR POSSIBLE CAUSES - Defective radio Equalizer Inoperative SYMPTOM * EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - Radio/CD cable loose/disconnected - DIN cable data bus (CAV 1) open - DIN cable data bus (CAV 3) open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 221 - DIN cable terminals shorted - DIN signal wires (CAVS 2, 4, and 5) open - DIN fused B(+) circuit open - DIN fused ignition switch output circuit open - DIN ground circuit open - DIN metal connectors open - Radio defective - Radio input control defective FF/RW Switch Inoperative SYMPTOM * FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM * HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12V output circuit defective, open - Radio ground circuit defective, open - Power relay output circuit defective, open - Radio 12V output circuit shorted to ground - Radio choke defective - Speaker power relay defective, open - Speaker power relay defective, open - Junction block defective, open circuit - Defective radio - Radio choke output circuit defective, open - Radio output circuits defective No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Door or quarter speaker (+) circuit defective, open - Door or quarter speaker (-) circuit defective, open - Door or quarter speaker (+) circuit open - Door or quarter speaker (-) circuit open - Instrument panel or pillar speaker (+) circuit open - Instrument panel or pillar speaker (-) circuit open - Door or quarter speaker defective - Speaker defective, no response Pause/Play Switch Inoperative SYMPTOM * PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 222 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector defective - Antenna connections defective - Hood ground defective - Ground circuit defective, open - Radio connectors not properly connected - Ignition / alternator system noise - Radio defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Ground circuit open - Instrument panel - pillar speaker defective - Radio choke output circuit open - Speaker (+) and (-) circuits shorted together - Inoperative speaker defective PWR Switch Inoperative SYMPTOM * PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Radio Error SYMPTOM RADIO ERROR POSSIBLE CAUSES - Defective radio Remote Controls Inoperative SYMPTOM * REMOTE CONTROLS INOPERATIVE POSSIBLE CAUSES - No response, CCD bus failure - Radio control harness defective, open - Radio control MUX circuit shorted - Remote control switch defective - MUX control clockspring defective - Radio control ground circuit to BCM open - Radio control MUX circuit open - Radio MUX control circuit defective - Body Control Module defective Scan Switch Inoperative SYMPTOM * SCAN SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 223 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM * SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Set Switch Inoperative SYMPTOM * SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Left door speaker shorted - Left front instrument panel speaker shorted - Right door speaker shorted - Right front instrument panel speaker shorted - Right front (-) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (+) circuit shorted to ground - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left door speaker defective, shorted - Left front instrument panel speaker defective, shorted - Left quarter speaker shorted - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear speaker shorted - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Right rear quarter speaker shorted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 224 - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear quarter speaker shorted - Left rear speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Right rear pillar speaker shorted - Radio output circuits defective Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right channel speaker shorted - Right instrument panel speaker defective, shorted - Right front (+) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (-) circuit shorted to ground - Right pillar speaker shorted - Right quarter speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Radio output circuits defective Tape Eject Switch Inoperative SYMPTOM * TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Tune Switch Inoperative SYMPTOM * TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM * VOL/TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM * 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 225 Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - BCM fails chime test Chime Inoperative With Driver Seat Belt Unfastened SYMPTOM * CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Ground circuit to left seat belt switch connector open - Left seat belt switch open - BCM not responding to belt switch - Body Control Module seat belt switch sense open - Seat belt switch sense circuit open Chime Inoperative With Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition Switch - key in switch shorted - BCM - no chime response - head/park lamps ON - BCM - key in sense shorted default - BCM - no response to park lamp switch - Chime inoperative with exterior lamps ON Chime Inoperative With Key In Ignition & Driver Door Open SYMPTOM * CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Ignition switch ground circuit open - Key in ignition switch sense circuit open - Ignition switch - key in switch open - BCM - no chime to key in ignition - BCM not responding to key in switch Chime Inoperative With L or R Turn Signal On For 1 Mile SYMPTOM * CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE POSSIBLE CAUSES - Junction block - Left turn signal open - Junction block - Right turn signal open - BCM - no response to turn signal - BCM fails speed test - Chime - speedometer problem - Chime inoperative - turn signal on for 1 mile Chime Inoperative With Low Oil Pressure SYMPTOM Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 226 * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With the Dome Lamps On SYMPTOM * CHIME INOPERATIVE WITH THE DOME LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM failed - door open & key out default - BCM - key in switch sense shorted default Chime Sounds With Driver Door Open & Key Out SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM - key in switch sense shorted default - BCM not responding to key out Chime Sounds With Driver Seat Belt Fastened SYMPTOM * CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch sense circuit shorted to ground - Left seat belt switch shorted - BCM - no response to seat belt fastened - BCM seat belt switch input shorted to ground Auto Headlamps Will Not Turn Off SYMPTOM * AUTO HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - No response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Auto headlamp signal circuit shorted to ground - Electrochromic mirror defective - sensor stuck ON (default) - BCM defective - auto headlamp sensor stuck ON Auto Headlamps Will Not Turn On SYMPTOM * AUTO HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - NO response (BCM) - CCD bus failure - NO response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Electrochromic mirror defective (default) - BCM defective - auto headlamp sensor Fog Lamps Will Not Turn Off SYMPTOM * FOG LAMPS WILL NOT TURN OFF Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 227 POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp switched ground circuit shorted to ground - Headlamp switch defective - foglamp switched ground Fog Lamps Will Not Turn On SYMPTOM * FOG LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp bulbs open - Fog lamp relay control circuit open - Fog lamp relay output circuit open - Fog lamp relay defective, open - Multifunction dimmer switch defective (open) default - Fog lamp switched ground circuit open - BCM defective - Headlamp relay control - Multifunction switch defective (fog lamp relay control) default - Headlamp relay control circuit (foglamps) open Headlamps Will Not Turn Off SYMPTOM * HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch sense circuit shorted to ground - Headlamp relay control circuit shorted to ground - Low beam relay control circuit shorted to ground - Low beam relay control circuit (QUAD) shorted to ground - Low beam headlamp relay (QUAD) defective, shorted - Low beam headlamp relay defective (shorted) by default - PDC defective (low beam headlamp relay connector shorted) - Headlamp switch defective - switch sense - BCM defective (headlamp switch sense function) by default - BCM defective (low beam relay control shorted) by default Headlamps Will Not Turn On SYMPTOM * HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Both low beam fuses open - Fused low beam output circuit open (both lamps inoperative) - Fused low beam output circuit open (one lamp inoperative) - Headlamp defective (by default) - Headlamp fuse open - Headlamp switch sense circuit open - Headlamps defective (by default) - Multifunction switch defective (default) - Headlamp relay control circuit open - Low beam relay control circuit (Chrysler) open - Low beam relay control circuit open - Low beam headlamp relay defective (by default) - Low beam relay defective - relay control function - PDC defective - B(+) circuit at low beam fuse terminal - Power Distribution Center defective (low beam relay CAV A) - Power Distribution Center defective (low beam relay CAV B) - Headlamp switch defective (by default) - BCM defective - headlamp switch sense function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 228 - BCM defective - headlamp switch sense stuck open - BCM defective - low beam relay control open Park Lamps Will Not Turn Off SYMPTOM * PARK LAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Park lamp relay control circuit shorted to ground - Park lamp relay output circuit shorted to voltage - Park lamp switch sense circuit shorted to ground - Park lamp relay defective - control shorted (by default) - Headlamp switch defective - shorted - BCM defective - park lamp switch sense closed (by default) Park Lamps Will Not Turn On SYMPTOM * PARK LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Fused park lamp output circuit open - Park lamp bulb defective (by default) - Park lamp fuse in PDC open - Both park lamp fuses open - Park lamp fuse open - Park lamp relay control circuit open - Park lamp relay output circuit open - Park lamp switch sense circuit open - Park lamp relay defective (control function) - PDC defective - other B(+) cavity - PDC defective - park lamp relay connector, fused B(+) - Headlamp switch defective - park lamps (by default) - BCM defective - park lamp switch sense stuck open - BCM defective - park lamp switch sense function - BCM defective - parklamp control function (by default) ABS Warning Lamp SYMPTOM * ABS WARNING LAMP POSSIBLE CAUSES - BCM connector observable defect - CAB connector observable defect - Fused ignition switch output circuit open - ABS warning lamp defective - ABS warning lamp driver circuit open - ABS warning lamp driver circuit shorted to ground - ABS warning lamp flashing - BCM defective - CAB defective Airbag Warning Lamp SYMPTOM * AIRBAG WARNING LAMP POSSIBLE CAUSES - Airbag warning lamp failure All Warning Lamps Out SYMPTOM * ALL WARNING LAMPS OUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 229 POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Information Center defective Engine Temperature Warning Lamp SYMPTOM * ENGINE TEMPERATURE WARNING LAMP POSSIBLE CAUSES - Engine temperature lamp staying on - Temperature lamp not working - Engine temperature lamp/bulb defective - Fused ignition switch output circuit open - Defective BCM - Engine temperature warning lamp driver circuit open - Temperature warning lamp driver circuit shorted to ground - Information Center defective - Body Control Module defect - Defective Information Center High Beam Indicator Lamp SYMPTOM * HIGH BEAM INDICATOR LAMP POSSIBLE CAUSES - Headlamps inoperative - Fused right highbeam output circuit open - Ground circuit open - High beam indicator bulb defective - Defective Information Center Low Oil Pressure Warning Lamp SYMPTOM * LOW OIL PRESSURE WARNING LAMP POSSIBLE CAUSES - Oil pressure low - Oil warning lamp/bulb defective - Oil level low - Defective oil pressure switch - Oil pressure switch sense circuit shorted to ground - Oil pressure switch sense circuit open - Oil pressure switch defective - BCM defective - Defective Information Center Red Brake Warning Lamp SYMPTOM * RED BRAKE WARNING LAMP POSSIBLE CAUSES - Park brake pedal problem - Vehicle equipped antilock brakes - Brake fluid level low - Red brake warn lamp/bulb defective - Ground circuit open - Brake fluid level switch defective - Defective ignition switch - Defective park brake switch - Red brake warning lamp circuit open - Red brake warning lamp circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 230 - Information Center faulty - Ignition switch defective - Red brake warning lamp driver circuit open - Red brake warning lamp driver circuit faulty Service Engine Soon Lamp SYMPTOM * SERVICE ENGINE SOON LAMP POSSIBLE CAUSES - DTC's are present - Bulb & socket defective - Service Engine Soon indicator lamp driver circuit open - Service Engine Soon indicator lamp circuit shorted to ground - Defective Information Center circuit board - Powertrain Control Module defective Turn Signal Indicator Lamp SYMPTOM * TURN SIGNAL INDICATOR LAMP POSSIBLE CAUSES - Turn signal lamps inoperative - Ground circuit open - Left turn signal circuit open - Right turn signal circuit open - Turn signal bulbs defective - Junction Block defective - BCM defective - Information Center defective Vehicle Theft Alarm Indicator SYMPTOM * VEHICLE THEFT ALARM INDICATOR POSSIBLE CAUSES - Vehicle theft alarm indicator defective All Gauges Inoperative SYMPTOM * ALL GAUGES NOT OPERATING POSSIBLE CAUSES - BCM instrument cluster circuit output defective - Instrument Cluster PC board defective - DRB shows ignition unlock closed - No response - CCD bus instrument cluster - Body computer odometer failure - RAM test failure - ROM test failure Cluster Illumination SYMPTOM * CLUSTER ILLUMINATION POSSIBLE CAUSES - No response - CCD bus instrument cluster - Headlamp switch ground circuit defective - Inoperative lamp defective - Headlamp switch defective - Junction block defective - Dimmer switch signal circuit open - Dimmer switch signal circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 231 - Instrument panel lamps driver circuit shorted to ground - Panel lamps driver circuit open - Park lamps not lighting - Instrument Cluster circuit board defective - BCM dimmer switch signal circuit output faulty - BCM defective - BCM defective by default - Body computer odometer failure - BCM dimmer switch signal circuit defective - Illumination panel fuse OK - Inoperative lamp ground circuit - RAM test failure - ROM test failure Cluster Warning Lamps Odometer and PRNDL Display SYMPTOM * CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY POSSIBLE CAUSES - Any one lamp/bulb defective - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Body computer odometer failure DTC - No response - CCD bus instrument cluster - Washer fluid level switch defective - BCM washer fluid switch sense circuit input defective - All segments fail to light - Faulty odometer and PRNDL lamp - Generator lamp failure - Instrument cluster printed circuit board defective Gauges Not Returning to Zero With Key Off SYMPTOM * GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF POSSIBLE CAUSES - Fused B(+) circuit open - No response - CCD bus instrument cluster - Instrument Cluster PC board defective - Body computer odometer failure - RAM test failure - ROM test failure One Gauge Not Operating Properly SYMPTOM * ONE GAUGE OPERATING IMPROPERLY POSSIBLE CAUSES - DRB reads active on the bus - DRB reads no vehicle speed sense signal code - IOD fuse is loose in junction block - Speedometer calibration out - Any one lamp/bulb defective - DRB reading not matching RPM - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Washer fluid level switch defective - Gauge pack defective - Speedometer/Odometer gauge pack defective - Tachometer calibration out - Cooling system condition faulty - DRB reads coolant temperature sensor code Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 232 - DRB reads engine temperature accurately - BCM instrument cluster circuit output defective - Body Control Module defective - Gauge pack defective - Instrument Cluster printed circuit board defective - DRB shows ignition unlock closed - BCM washer fluid level switch sense circuit input defective - All segments fail to light - BCM temperature gauge input defective - Faulty odometer and PRNDL lamp - Generator lamp failure - PCM defective - Pinion factor failure Trip and Rest Button(S) SYMPTOM * TRIP AND RESET BUTTON(S) POSSIBLE CAUSES - Trip & reset button(s) defective Courtesy Lamps Inoperative W/Dome Lamp Switch SYMPTOM * COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH POSSIBLE CAUSES - Courtesy lamp switch sense circuit open - Headlamp switch defective - courtesy lamp function open - BCM defective - courtesy lamp switch sense (by default) - BCM defective - dome lamp switch function Courtesy Lamps Inoperative With Any Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH ANY DOOR POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay control circuit open - Switched courtesy lamp relay control circuit open - Junction block defective - lamp relay fused B(+) (CAV 87) open - Courtesy lamp relay defective - coil open - Junction block defective - lamp relay fused B(+) (CAV 30) open - Junction block defective - lamp relay fused B(+) (CAV 86) Open - Headlamp switch defective - open - BCM defective - lamp relay control function (by default) - BCM defective - driver door ajar switch status Courtesy Lamps Inoperative With Driver Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR POSSIBLE CAUSES - Driver door ajar switch defective, open - Driver door ajar switch sense circuit open - Left front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Left Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR POSSIBLE CAUSES - Left sliding door ajar switch sense circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 233 - Left sliding door ajar ground circuit open - Left sliding door ajar switch defective, open - BCM defective Courtesy Lamps Inoperative With Liftgate SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LIFTGATE POSSIBLE CAUSES - Liftgate ground circuit open - Liftgate ajar switch open - ajar switch disconnected - Liftgate ajar switch sense circuit open - BCM defective, open Courtesy Lamps Inoperative With Passenger Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR POSSIBLE CAUSES - Passenger door ajar switch defective, open - Passenger door ajar switch sense circuit open - Right front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Right Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR POSSIBLE CAUSES - Right sliding door ajar switch defective, open - Right sliding door ajar switch sense circuit open - Right sliding door ajar ground circuit open - BCM defective, open Courtesy Lamps On at All Times SYMPTOM * COURTESY LAMPS ON AT ALL TIME POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay output circuit shorted to B(+) - Courtesy lamp relay control circuit shorted to ground - Switched courtesy lamp relay control circuit shorted to ground - Courtesy lamp relay defective - coil shorted - Headlamp switch shorted - BCM defective - relay control shorted (by default) Illuminated Entry Inoperative With Driver Door Key Cylinder SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER POSSIBLE CAUSES - Driver door key switch unlock position stuck - Driver door key cylinder switch defective - Driver door key switch sticking Illuminated Entry Inoperative With RKE Transmitter SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 234 - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective unlock switch - RKE module default replacement - RKE module defective CMTC Avg MPH/Fuel Economy Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR WRONG POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative CMTC Elapsed Time Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective BCM / Indicator lights CMTC Fails to Respond to Instrument Cluster Dimming SYMPTOM * COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Trip Odometer Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE/WRONG. POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative Compass/Mini-Trip Computer Displaying OC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING OC POSSIBLE CAUSES - Open sensor ground circuit - Ambient Temperature Sensor defective - Open Ambient Temperature Sensor signal circuit - Defective Compass/Mini-Trip Module - sensor ground circuit. Compass/Mini-Trip Computer Displaying SC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING SC POSSIBLE CAUSES - Defective Ambient Temperature Sensor - Ambient Temperature Sensor signal circuit shorted to ground - Compass/Mini-Trip Module default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 235 Compass/Mini-Trip Computer Segments Fail to Light SYMPTOM * COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - segments fail to light Compass/Mini-Trip Computer Shows Failed SYMPTOM * COMPASS/MINI-TRIP COMPUTER SHOWS FAILED POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - shows failed Compass/Mini-Trip Computer Switch Inoperative SYMPTOM * COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Incorrect Ambient Temperature Readings SYMPTOM * INCORRECT AMBIENT TEMPERATURE READINGS POSSIBLE CAUSES - Open sensor ground - defective CMTM - Sensor ground circuit partial short to ground - Defective Ambient Temperature Sensor/Road test - Ambient Temperature Sensor signal circuit partial short - Ambient Temperature Sensor signal circuit shorted - Defective Compass/Mini-Trip Module - Defective Compass/Mini-Trip Module sensor ground circuit Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH POSSIBLE CAUSES - Junction block defective - Door unlock relay output circuit open - Door unlock relay output circuit resistance low Additional All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door unlock relay control inoperative at BCM - Door unlock relay defective - Door unlock relay coil resistance out of tolerance - Door unlock relay output circuit shorted to ground Additional All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 236 POSSIBLE CAUSES - Passenger door switch MUX shorted to battery - Door lock switch resistance high in unlock position - Driver door switch MUX circuit shorted to battery - Liftgate switch MUX shorted to battery - BCM door lock relay control circuit inoperative - Liftgate switch MUX at BCM defective - Door lock relay control ground circuit open - Door lock relay defective - Fuse # 26 defective - Fused B(+) circuit open - Fused B(+) circuit shorted to ground - Ground circuit open at door lock relay connector Additional All Doors Fail to Lock and Unlock From One Switch SYMPTOM ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH POSSIBLE CAUSES - Door key cylinder switch connector circuit ground circuit open - Door key cylinder switch defective - Liftgate key cylinder switch defective - Liftgate switch MUX shorted to battery - Door switch MUX circuit to BCM open - Driver door switch MUX circuit open at BCM connector - Liftgate switch MUX circuit open at BCM connector - Liftgate switch MUX circuit to BCM open - Passenger door switch MUX circuit open at BCM connector - Passenger door switch MUX circuit to BCM open - Door lock switch connector ground circuit open - Door lock switch defective - Door lock switch MUX circuit open - Door locks inoperative from key cylinder switch - Door switch MUX circuit shorted to battery Additional All Doors Failing to Lock From Any Switch SYMPTOM ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door lock relay control circuit from BCM fails - Key - in ignition switch circuit to BCM defective - Door lock relay does not operate - Door lock relay coil resistance out of tolerance - Door lock relay output shorted to ground - Ignition switch defective - Key - in ignition switch sense circuit shorted to ground Additional Driver Door (w/RKE) Failing to Unlock From Any SW SYMPTOM ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Driver door unlock relay coil resistance out of tolerance - Driver door unlock relay defective - Driver door unlock relay output circuit shorted to ground - Voltage too low at junction block fused B(+) circuit Additional One Door Fails to Lock and Unlock From Any Switch SYMPTOM ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 237 POSSIBLE CAUSES - RKE equipped door lock fails to lock & unlock - Door lock motor defective - Driver unlock relay ground open in junction block - Door lock relay output circuit open - Door unlock relay output circuit open - Driver door unlock relay open All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective door unlock switch - RKE module default replacement - RKE module defective All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Defective door lock switch - Defective unlock switch All Doors Fail to Lock and Unlock From One Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Lock From Any Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 238 - Defective unlock switch All Doors Failing to Lock From One Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Unlock From One Switch SYMPTOM * ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Automatic Door Locks Do Not Lock Over 15 MPH SYMPTOM * AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH POSSIBLE CAUSES - Link to body communication bus inoperative - TPS malfunction causes door lock problem - VSS malfunction causes door lock problem - Auto door lock not enabled Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - BCM defective - BCM sends wrong key - in ignition status - BCM a connector terminals damaged - Ignition switch open - Key - in ignition switch ground circuit open - Key - in ignition switch sense circuit open Driver Door (w/RKE) Failing to Unlock From Any Switch SYMPTOM * DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch One Door Fails to Lock and Unlock From Any Switch SYMPTOM * ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 239 This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Remote Keyless Entry Problem SYMPTOM * RKE PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - RKE module default replacement - RKE module defective Front Wiper Operating Constantly W/Switch In Off Position SYMPTOM * FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION POSSIBLE CAUSES - Front wiper ON/OFF relay control circuit shorted to ground - Defective wiper ON relay/substitute relay - Defective multifunction switch/voltage - High/Low wiper relay HI speed output circuit shorted to voltage - High/Low wiper relay LO speed output circuit shorted to voltage - Defective BCM - 100 ohms default Front Wipers Not Parking In Off Position SYMPTOM * FRONT WIPERS NOT PARKING IN OFF POSITION TEST NOTE This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN POSSIBLE CAUSES - Wiper park switch toggle closed/open - Open wiper park switch sense circuit - Defective BCM - wiper park switch - Defective wiper motor/wiper park switch Front Wipers Not Working at All SYMPTOM * FRONT WIPERS NOT WORKING AT ALL POSSIBLE CAUSES - Open wiper on relay control circuit - BCM/wiper relay - Defective wiper ON relay - BCM/ground - Front wiper switch MUX circuit shorted to ground - Open front wiper switch MUX circuit between switch and BCM - Defective High/Low wiper relay - relay connector - Defective multifunction switch/front wiper switch - High/Low wiper relay HI speed output circuit shorted to ground - High/Low wiper relay LO speed output circuit shorted to ground - Open ground circuit/lights - Open High/Low relay LO speed output circuit between High/Low relay and wiper motor - Open fused ignition switch output circuit/multifunction switch - Defective Power Distribution Center - relay connector Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 240 - Defective Power Distribution Center - front wiper relay - Defective Power Distribution Center - wiper ON relay - Defective Power Distribution Center - wiper relay - Defective Power Distribution Center - H/L relay - Defective Power Distribution Center - B(+) circuit. - Defective wiper motor/harness - Defective BCM/wiper relay - Defective BCM/front wiper MUX - Defective BCM/sensors - Defective wiper motor ground circuit. Front Wipers Not Working In High Speed Mode SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE POSSIBLE CAUSES - Open HI/LO wiper relay control circuit - Defective HI/LO wiper RELAY - Wiper switch - Open wiper HI/LO relay HI speed output circuit - Defective multi - FUNCT switch/ ground circuit - Defective power DIST CNTR-H/L WPR RLY - Defective wiper Motor/HI speed output circuit - Open ground circuit/Multi - Function switch Front Wipers Not Working In Intermittent Mode SYMPTOM * FRONT WIPERS NOT WORKING IN INTERMITTENT MODE POSSIBLE CAUSES - Defective multifunction switch/positions - Defective BCM/wiper positions - Defective multifunction switch/Default Front Wipers Not Working In Low Speed Mode SYMPTOM * FRONT WIPERS NOT WORKING IN LOW SPEED MODE POSSIBLE CAUSES - High/Low wiper relay control circuit shorted to ground - Defective High/Low wiper relay - fused ignition switch - Open High/Low wiper relay - LO speed output circuit - Defective wiper motor/LO speed output circuit Rear Washer Motor Inoperative SYMPTOM * REAR WASHER MOTOR INOPERATIVE POSSIBLE CAUSES - Open rear washer motor control circuit - Defective rear washer motor/jumper - Open fused ignition switch output circuit/voltage - Defective HVAC Control Module / 3.8 volts - Defective BCM - washer motor operate Rear Wiper Not Parking In the Off Position SYMPTOM * REAR WIPER NOT PARKING IN THE OFF POSITION POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective HVAC Control Module/switch indicator lights - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 241 - Defective BCM/washer motor run - Defective BCM/cycle on default - Defective BCM/rear wiper switch voltage - Defective rear wiper motor/test light Rear Wiper Not Working at All SYMPTOM * REAR WIPER NOT WORKING AT ALL POSSIBLE CAUSES - Open rear wiper motor control circuit - Open rear wiper switch MUX circuit - Open ground circuit/rear wiper motor - Open fused ignition switch output circuit/fuse # 6 - Open fused ignition switch output circuit/fuse # 8 - Shorted fused ignition switch output circuit/fuse # 6 - Defective rear wiper motor/motor control - Defective HVAC Control Module/default - Defective HVAC Control Module/rear wiper switch MUX - Defective BCM/rear wiper switch MUX - Defective BCM/rear wiper motor - Defective HVAC Control Module/21-Way connector Rear Wiper Not Working In the Intermittent Mode SYMPTOM * REAR WIPER NOT WORKING IN THE INTERMITTENT MODE POSSIBLE CAUSES - Defective rear wiper motor/intermittent switch - Defective HVAC Control Module/indicator light - Defective HVAC Control Module/rear wiper switch - Defective BCM/test light default Rear Wiper/Wash Working Continuously SYMPTOM * REAR WIPER/WASH WORKING CONTINUOUSLY POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default - Defective BCM/washer motor run - Defective BCM/rear wiper switch voltage Wiper/Wash Function Not Working Properly SYMPTOM * WIPER/WASH FUNCTION NOT WORKING PROPERLY POSSIBLE CAUSES - Defective washer motor/washer pump control - Operate wipers - Open washer pump control circuit - Defective multifunction switch/washer pump control - Open fused ignition switch output circuit - Defective junction block/BCM - Defective junction block/block connector - Defective BCM/junction block - Defective BCM/stalk switch - Fused ignition switch output circuit shorted to ground - Open washer pump control circuit/multifunction switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 242 Body Control Module: Component Tests and General Diagnostics Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 243 Body Control Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 244 Body Control Module: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) Body Control Module - Location 4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Refer to Instrument Panel and Systems, Body Control Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 245 Body Control Module: Tools and Equipment DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Power Distribution Center & Powertrain Control Module (PCM) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 251 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 253 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 254 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 256 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 258 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 259 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 260 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 262 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 263 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 264 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 265 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 267 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 268 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 270 Powertrain Control Module C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 271 Powertrain Control Module: Description and Operation OPERATION Powertrain Control Module The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet changing engine operating conditions. During the crank-start period the PCM advances ignition timing a set amount. During engine operation, the amount of spark advance provided by the PCM is determined by the following input factors: available manifold vacuum - barometric pressure - engine coolant temperature - engine RPM - throttle position The PCM also regulates the fuel injection system. Refer to the Fuel Injection. The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 272 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection Power Distribution Center Retaining Screws 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket. Battery Heat Shield 3. Remove heat shield from battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 273 Battery Clamp 4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle. PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 274 PCM 40-way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both way connectors. PCM Removal/Installation 9. Remove 3 screws holding PCM to fender. 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 278 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 281 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 284 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 285 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 286 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 287 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 289 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 290 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 292 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 294 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 296 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 297 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 298 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 299 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 300 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 301 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 304 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 305 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 310 Power Distribution Center -- Sheet 8w-10-2 The fuel pump relay is located in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 311 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 312 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit contains a 9 amp fuse. The fuse is located in the PDC. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 313 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 314 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 318 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 321 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 323 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 324 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 326 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 329 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 330 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 331 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 332 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 334 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 335 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 336 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 337 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 338 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 339 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 340 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 341 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 344 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 345 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 350 Air Bag Control Module: Diagrams Airbag Control Module C1 Airbag Control Module C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 351 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs. The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or serious injury, caused by a frontal impact of the vehicle. The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 352 Air Bag Control Module: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 353 Air Bag Control Module: Service and Repair Negative Battery Cable WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Remove forward lower console from instrument panel, refer to Instrument Panel and Systems for proper procedures. Heat Duct 2. Remove screw holding lower heat duct to instrument panel support. 3. Remove heat duct from instrument panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 354 Instrument Panel Supports 4. Remove two bolts holding top of right support to instrument panel. 5. Remove two bolts holding bottom of right support to floor pan. 6. Separate right instrument panel support from vehicle. ACM Connectors 7. Disconnect two connectors from ACM. 8. Remove four bolts holding the ACM bracket assembly to floor. INSTALLATION WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET INSTALLED. CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 355 For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with the proper screws and tighten to 8.5 to 11.9 Nm (75 to 105 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 360 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 361 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 362 Starter Relay: Description and Operation STARTER RELAY-PCM OUTPUT Double Start Override is a feature that prevents the starter from operating if the engine is already running. This feature is accomplished with software only. There was no hardware added because of this feature. To incorporate the unique feature of Double Start Override, it was necessary to use the PCM (software) to control the starter circuit. To use the PCM it was necessary to separate the starter relay coil ground from the park neutral switch. The starter relay ground is now controlled through Pin 60 of the PCM. This allows the PCM to interrupt the ground circuit if other inputs tell it that the engine is turning. If the starter system is operating properly, it can be assumed that the override protection is also working. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 363 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED. Starter Relay Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +-5 Ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications Control Module: Specifications Sixty-Way Connector 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications > Page 369 Transmission Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 372 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 375 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 377 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 378 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 380 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 382 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 383 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 384 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 385 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 386 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 387 Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 388 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 389 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 390 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 391 Control Module: Description and Operation AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT The electronic automatic transaxle control module and the PCM supply information to each other through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the information when adjusting the fuel and ignition strategy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 392 Control Module: Service and Repair OVERVIEW Do not interchange Transmission Control Modules with previous year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. REMOVAL Fig. 27 1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then disconnect the 60 way connector on Transmission Control Module. Fig. 28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 393 Fig. 29 2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28 and 29). INSTALLATION 1. To install, reverse removal procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 397 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 398 Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 399 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY The transmission control relay is located in the Power Distribution Center (PDC) on the left side of the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in mode. After a controller reset (ignition key turned to the run position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 404 Heated Glass Element Relay: Diagrams Junction Block Rear Window Defogger Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Front Windshield Wiper Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 409 Wiper Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 413 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 414 Wiper Relay: Diagrams Power Distribution Center Wiper High/Low Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 415 Wiper On/Off Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Arm/Disarm Switch: Diagrams Driver Door Arm/Disarm Switch Passenger Door Arm/Disarm Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Open the front door. Front Door Ajar Switch 3. Remove the screw holding the door ajar switch to the door B-pillar. 4. Remove the door ajar switch from the B-pillar. 5. Disconnect the wire connector from the back of the ajar switch and remove the switch. INSTALLATION For installation reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 425 Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Release the sliding door latch and allow back of the door to pop open. Sliding Door Ajar Switch 3. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar switch from quarter panel opening. 4. Disconnect the wire connector from the back of the ajar switch. 5. Remove the sliding door ajar switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. Negative Battery Cable 2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair Lock Cylinder Switch: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and sound pad. 3. Close the door window. 4. Disconnect the door key cylinder switch wire connector from the door harness and wiring clip from the impact beam. 5. Remove the front door outside handle from the door. Door Lock Cylinder Switch 6. Disengage the lock tab holding switch to the back of the lock cylinder. 7. Remove the switch from the door handle. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation Remote Switch: Description and Operation SYSTEM OPERATION Remote Radio Switches Remote Radio Switch Operational View A remote radio control switch option is available on LXI models sold in North America with the AM/FM/ cassette/5-band graphic equalizer with CD changer control feature (RBN sales code), or the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 435 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switches 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. REMOTE RADIO SWITCH TEST Switch position = Resistance Volume Up = 7320 Ohms Volume Down = 1210 Ohms Seek Up = 4530 Ohms Seek Down = 2050 Ohms Pre-set station advance = 10 Ohms NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right"/Left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity If OK, refer to the proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK, repair the open circuit as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 436 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from the remote radio switch(s). 8. Remove three screws securing steering wheel rear cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side of switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be careful to index them correctly before pressing them into place. Tighten the airbag module mounting screws to 10.2 Nm (90 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Diagrams Trunk/Liftgate Sensor/Switch (For Alarm): Diagrams Hood Ajar Switch Liftgate Arm/Disarm Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch from the vehicle. 3. Disconnect the wire connector from the liftgate ajar switch. Liftgate Ajar Switch 4. Remove the screw holding the ajar switch to the liftgate latch and remove the switch. INSTALLATION For installation, Reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page 442 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Key Cylinder Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate trim panel. 3. Disconnect the liftgate key cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 4. Remove the liftgate outside handle. Liftgate Cylinder Lock Switch 5. Disconnect the lock tab holding the switch to the back of lock cylinder and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. Negative Battery Cable 2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 451 Power Door Lock Switch: Testing and Inspection 1. Remove door lock/power window switch bezel assembly from door. Refer to Power Door Lock Switch Replacement. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch Door Lock Switch Test 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. Refer to Door Lock Switch Test. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the parameters shown replace the door lock switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 452 Power Door Lock Switch: Service and Repair The Power Door Lock Switch is the only serviceable part on the power door lock / window switch bezel.The window switches, window lock - out, and power vent window switch is serviced with the bezel. REMOVAL Negative Battery Cable 1. Disconnect and isolate the negative battery cable. 2. Open left door, remove screw cover near inside door release handle. 3. Remove two screws to door lock / window switch bezel. One under the screw cover removed in previous step and one to the rear of the front door vent opening. 4. Pull out and up on bezel to release from door trim panel. 5. Disconnect door lock switch connector. 6. Remove two door lock switch retaining screws and remove switch from vehicle. INSTALLATION 1. For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection 1. Remove power mirror switch. Refer to Instrument Panel and Systems for Replacement Procedures. 2. Disconnect wiring harness at switch connector. Mirror Switch Test 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Power Mirror Switch: Service and Repair Power Mirror Switch REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. Power Mirror Switch 3. Disconnect wire connector from back of power mirror switch. 4. Disengage lock tabs above and below the mirror switch. 5. Pull power mirror switch from headlamp switch bezel. The power mirror switch bezel is mounted to the bottom of the instrument cluster bezel. 6. Remove power mirror switch. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 458 Power Mirror/Window Switch Refer to Instrument Panel and Systems for service procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 459 Power Mirror Switch: Service and Repair Power Mirror Switch Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove instrument cluster bezel. Power Mirror Switch Lamp 4. Rotate bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from back of power mirror switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch: Testing and Inspection 1. Remove seat switch from seat. Refer to Seat Switch Replacement. Seat Switch Test 2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the switch positions, replace switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 463 Power Seat Switch: Service and Repair REMOVAL AND INSTALLATION Negative Battery Cable 1. Disconnect and isolate the battery negative cable. Bucket See Cushion Side Cover Remove/Install 2. Remove seat cushion side cover. Set Switch Wire Connector 3. Disconnect the wire connector to the seat switch and remove side cover from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation SYSTEM OPERATION The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If either switch or LED is faulty, the switch must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 467 Seat Heater Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion side cover. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open circuit as required. 4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK, replace the faulty switch. 5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 468 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755), gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out switch from rear of switch bezel. 5. Remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Liftgate Ajar Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for replacement of the brake fluid level switch. REMOVAL Fluid Level Sensor Electrical Connection 1. Remove wiring harness connector from brake fluid reservoir level switch. Master Cylinder Brake Fluid Level Switch 2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert the brake fluid level switch into brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to the brake fluid reservoir. 2. Connect the vehicle wiring harness connector to the brake fluid level switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side > Page 481 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 482 Traction Control Switch: Testing and Inspection Traction Control Switch Connector 1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading between pins. Traction Control Switch Continuity Switch Position = Continuity between Actuated = Pins 1 and 2 Illumination = Pins 1 and 3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 483 Traction Control Switch: Service and Repair Battery Negative Cable REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the over steering column bezel. 3. Remove the two screws attaching traction control switch to the bezel. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Allowable Resistance 900 - 1300 ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 488 Wheel Speed Sensor: Mechanical Specifications Front Rear Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in To Axle Or Steering Knuckle Mounting Bolt 105 in.lb 105 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Front Wheel Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 491 Rear Wheel Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 494 Wheel Speed Sensor: Diagrams Rear Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 495 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor (FWD) One Wheel Speed Sensor (WSS) and one tone wheel are located at each front and rear wheel. Each front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is part of the outboard constant velocity joint. The rear wheel speed sensor on rear disc brake applications is mounted to the rear disc brake adapter. The rear tone wheel is an integral part of the rear wheel hub and bearing. The wheel speed sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel speed sensor. The CAB converts the AC signal into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. Correct ABS operation is dependent on accurate wheel speed signals. The vehicle's tires and wheels all must be the same size and type to generate accurate signals. Variations in tire and wheel size can produce inaccurate wheel speed signals. Improper speed sensor-to-tone wheel clearance can cause erratic speed sensor signals. The speed sensor air gap is not adjustable, but should be checked when applicable. Wheel speed sensor-to-tone wheel clearance specifications can be found in Specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 496 Wheel Speed Sensor: Testing and Inspection Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. missing, chipped, or broken teeth - contact with the wheel speed sensor - wheel speed sensor to tone wheel alignment - wheel speed sensor to tone wheel clearance - excessive tone wheel runout - tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement on front-wheel-drive models, the tone wheel is serviceable separately. If a rear tone wheel is found to need replacement on all-wheel-drive models, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Front Speed Sensor Cable Channel Bracket 3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame rail. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector. Speed Sensor Cable To Vehicle Wiring Harness 4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect speed sensor cable from vehicle wiring harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 499 Front Wheel Speed Sensor Attaching Bolt 5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. Front Wheel Speed Sensor Cable Routing 7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front wheel speed sensor assembly from the vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut tower. CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the channel bracket. 2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4. Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link. 5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor attaching bolt to a torque of 12 Nm (105 inch lbs.) 6. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (.047 inches). 7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 500 Rear REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. CAUTION: When unplugging speed sensor cable from vehicle wiring harness, be careful not to damage pins on the electrical connectors. Also inspect connectors for any signs of previous damage. Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during removal of the speed sensor cable. Speed Sensor Cable Attachment To Brake Flex Hose 4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 501 Right Rear Speed Sensor Cable Routing 5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the axle flange, the brake tube clip and the routing clip from the track bar bracket on the axle. Rear Speed Sensor Routing Brackets And Clips 6. Remove the 2 rear wheel speed sensor cable/brake tube routing clips. Then unclip the speed sensor cable from the routing clips on rear brake tube. CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor head in an attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the sensor from side to side until free. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 502 Rear Wheel Speed Sensor Attaching Bolts 7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not come loose, do not use pliers. Tap with screw driver and hammer. 8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed sensor assembly from vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head. Note the plastic anti rotation pin must be fully seated prior to installing the attaching bolt. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. Rear Wheel Speed Sensor Attaching Bolts 2. Install the wheel speed sensor head to bearing flange attaching bolt. Tighten the attaching bolt to a torque 12 Nm (105 inch lbs.) 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inches). 4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle. The rear wheel speed sensor cable should be routed under the rear brake tube. CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during installation of the wheel speed sensor cable. 5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 503 CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the vehicle wiring harness, do not force the connectors together. If the connectors are forced together, damage to the connectors will occur. 7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into the body hole. 9. Install the tire and wheel assembly on vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 504 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement This procedure is for the removal of the ABS rear tone wheel from the rear hub and bearing on front wheel drive vehicles. Vehicles equipped with AWD have a tone wheel mounted on the driveshaft outer constant velocity joint and it is serviced with the driveshaft. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly. 3. Remove rear brake drum from the hub/bearing assembly. Rear Wheel Speed Sensor 4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing assembly. Rear Hub/Bearing Mounting Bolts 5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 505 Removing Rear Hub/Bearing From Axle 6. Remove the hub/bearing assembly from the rear axle and brake support plate. Tone Wheel Removal From Hub/Bearing Assembly 7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage by the vise jaws. Mount the hub/bearing assembly in a vise. Using Puller, Special Tool C-4693 installed as shown remove the tone wheel from the hub/bearing assembly. INSTALL Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 506 Installing Tone Wheel On Hub/Bearing Assembly 1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3. Position Driver, Special Tool 6908-1 with undercut side facing up on top of the tone wheel. Correctly Installed Tone Wheel 2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3. Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts into hub/ bearing assembly. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 7. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 8. Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inches). 9. Install the brake drum onto the rear hub/bearing assembly. 10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust the rear brakes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Temperature Sensor 7 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 512 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 513 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 514 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 515 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40° F to 265° F). The engine coolant temperature sensor provides an input voltage to the PCM. As coolant temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle speeds until normal operating temperatures are reached. The engine coolant sensor is also used for cooling fan control. Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 516 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant Temperature Sensor 1. With the key off, disconnect wire harness connector from coolant temperature sensor. Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter should read as follows: a. ECT STET at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 517 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Speed Control Switches Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 525 Cruise Control Switch: Description and Operation DESCRIPTION There are two separate switch pods that operate the speed control system. OPERATION The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 526 Cruise Control Switch: Testing and Inspection Refer to the appropriate Powertrain Diagnostics for switch test values. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 527 Cruise Control Switch: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove airbag/horn pad from steering wheel, refer to Airbags and Seat Belts/Airbags for proper procedures. 4. Disconnect wire connector from horn switch, airbag, and speed control switches. Speed Control Switches 5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control switch from airbag/horn pad. INSTALLATION Reverse the preceding operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 536 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 542 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions Roof Rack Frame: All Technical Service Bulletins Roof Panel - Wavy or has Depressions BULLETIN NUMBER: 23-11-00 GROUP: Body DATE: Mar.24, 2000 SUBJECT: Roof Panel Wavy Or Has Depressions MODELS: 1996 - 2000 (NS) Town & County/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-28-96, DATED MAY 3, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. OVERVIEW: This bulletin involves applying heat to the roof panel to remove depression(s). This Repair Procedure is not intended to be used to correct any type of impact/damage caused dents. SYMPTOM/CONDITION: The roof panel surface exhibits waviness or depression(s) near the front of the character features or skid strip for roof rack equipped vehicles. Typically the shape of the depression or waviness will be elliptical or along a line across the vehicle. The depression(s) will go away on their own as the vehicle is exposed to higher ambient temperatures and sun load. DIAGNOSIS: While standing in front of the vehicle, visually inspect the roof panel, if any depression(s) or waviness is seen in one or both areas shown in Figure 1, perform the following Repair Procedure only if the customer is unwilling to wait for higher ambient temperatures to remove the depression(s). EQUIPMENT REQUIRED. Heat Gun such as Pentastar Service Equipment (PSE) W-PH12OO REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions > Page 548 Figure 1 1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped. 2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop" when the depression removal is complete. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions > Page 554 Figure 1 1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped. 2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop" when the depression removal is complete. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Page 555 Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation OPERATION The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a Vehicle Speed Sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Diagnostic Procedures for diagnosis and testing of this component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Page 556 Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection For diagnosis and testing of the Vehicle Speed Signal (VSS), refer to the appropriate Powertrain Diagnostic Procedures. Also refer to the DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Gauge Sending Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 561 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 562 Oil Pressure Sender: Diagrams Engine Oil Pressure Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation AIR CONDITIONING SWITCH SENSE-PCM INPUT When the air conditioning or defrost switch is put in the ON position and the low pressure switch, combination valve, and high pressure switch close, the PCM receives an A/C input. After receiving this input, the PCM activates the A/C compressor clutch by grounding the A/C clutch relay. The PCM also adjusts idle speed to a scheduled RPM to compensate for increased engine load. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Lamp Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel HVAC Control. Refer to Radio Bezel and HVAC Control Replacement. Rear Heater - A/C Switch Lamp Bulb 3. Rotate bulb socket counterclockwise one quarter. 4. Pull bulb socket from switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement > Page 569 Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel and HVAC Control. Rear Heater - A/C Switch 3. Remove screw holding rear heater-A/C switch to radio bezel HVAC Control. 4. Disengage hook holding bottom of switch to radio bezel HVAC Control. 5. Remove switch from radio bezel HVAC Control. INSTALLATION For instrument, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 573 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor (Sensor Side) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 574 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Raise and support vehicle on safety stands. 3. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 4. Remove sensor from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION Rear Blower Speed Switch The rear blower speed switch controls the rear blower with the choice of low and high speeds. when the switch is on it allows the blower speed switch located on the rear headliner to control rear blower speed. This switch will override the rear headliner blower switch. For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from the A/C control module. For service procedures, refer to Instrument Panel And Gauges. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation SYSTEM OPERATION Evaporator Probe The Evaporator probe is located on the HVAC. The probe prevents evaporator freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The probe monitors the temperature of the refrigerant after expansion. The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit and cannot be adjusted or repaired. It must be replaced if found defective. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Temperature Diagnostics The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: - Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared. To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. Display Sequence is as follows: - REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one 5 digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cooldown test is exited. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 583 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Test Evaporator Probe: Resistance Vs. Temperature Chart Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 584 Resistance Measurement Table The evaporator probe is located in the unit housing and placed in the evaporator fins. The probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature drops below freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. A malfunctioning evaporator probe may show symptoms such as: - Ice blocking the airflow, or frost exiting out of the outlets and vents - No air conditioning operation - No power to the compressor clutch during A/C selection The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) during testing. 1. Place the vehicle in a location out of direct sunlight and allow the vehicle to come to ambient temperature (the engine can remain warm). 2. With the engine OFF, lower the windows, and turn on the interior blower (with the system in Fresh Air mode). 3. Place a thermometer in one of the Instrument Panel outlets, and a second one in the intake duct (plenum area by the windshield wipers). 4. Allow the blower to run until both temperatures readings are within 2° F of one another and constant. 5. Remove the electrical connector from the evaporator probe and measure the resistance of the probe with a multimeter. 6. Consult the temperature/resistance chart and table to determine whether the resistance is within specification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 585 If the measurements fall outside the specifications, replace the evaporator probe. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Page 586 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the glove box. Refer to Instrument Panel and Systems. Evaporator Probe Connector 2. Disconnect the evaporator probe connector. Evaporator Probe Grommet 3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing. Evaporator Probe 4. Remove evaporator probe from evaporator. INSTALLATION For installation, reverse the above procedures. Three holes are provided in evaporator for probe location. When reinstalling probe, use a different hole than original one. If a new evaporator is installed, insert the probe in the uppermost hole provided. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications Low psi control opens < 29.4 psi High psi control opens > 450 psi Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 590 A/C Pressure Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 591 Refrigerant Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION A/C Pressure Transducer A/C Pressure Transducer The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system. The transducer is located on the liquid line. The pressure transducer turns off the voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The transducer also is used to adjust condenser fan speeds and will turn off compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated unit. It must be replaced if defective. O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for the transducer. AIR CONDITIONING PRESSURE TRANSDUCER-PCM INPUT The Powertrain Control Module (PCM) monitors the A/C compressor discharge (high side) pressure through the air conditioning pressure transducer. The transducer supplies an input to the PCM. The PCM engages the A/C compressor clutch if pressure is sufficient for A/C system operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 592 Refrigerant Pressure Sensor / Switch: Testing and Inspection The work area temperature must not be below 10° C (50° F) to test the compressor clutch circuit. Before starting to test the transducer ensure that the wire connector is clean of corrosion and connected properly. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install scan tool (DRB): - Go to main menu - Select stand alone scan tool (DRB) - Select refer to the proper year diagnostics - Select climate control - Select sensor display - Select A/C high side volts For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition and will not allow the compressor to cycle. A/C Pressure Transducer Voltage Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s): 1. Connect a tachometer and manifold gauge set. 2. Set control to A/C, RECIRC, and PANEL, temperature lever on full cool and blower on high. 3. Start engine and hold at 1000 rpm with A/C clutch engaged. 4. Engine should be warmed up with doors and windows closed. 5. Insert a thermometer in the left center A/C outlet and operate the engine for five minutes. The A/C clutch may cycle depending on ambient conditions. 6. With the A/C clutch engaged, compare the discharge air temperature to the A/C Performance Temperatures table. A/C Performance Temperature Chart 7. If the discharge air temperature fails to meet the specifications in the performance temperature chart. Refer to the Refrigerant Service Procedures for further diagnosis. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 593 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect the wire connector at the pressure transducer. A/C Pressure Transducer Removal 2. Using an open end wrench, remove the transducer from the liquid line. INSTALLATION 1. Replace transducer O-ring. 2. For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Brake Switch (Typical) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 605 Brake Light Switch: Diagrams Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 606 Brake Light Switch: Description and Operation DESCRIPTION The switch is mounted on the brake pedal mounting bracket under the instrument panel. OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM monitors the state of the dual function stop lamp switch. Refer to the stop lamp switch service and adjustment procedures. BRAKE SWITCH-PCM INPUT When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through control of the idle air control motor. The brake switch is mounted on the brake pedal support bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 607 Brake Light Switch: Testing and Inspection Stop Lamp Wiring 1. Remove the stop lamp switch refer to Stop Switch Replacement. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 608 Brake Light Switch: Adjustments 1. Remove stop lamp switch from its bracket by rotating it approximately 30 in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30 to lock the switch into the bracket. Stop Light Switch Location In Vehicle CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 609 Brake Light Switch: Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 618 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 619 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 620 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 621 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 622 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 623 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 629 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 630 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 631 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 632 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 633 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 634 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Glove Box Lamp And Switch 2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch. 5. Remove glove box lamp and switch. Glove Box Lamp 6. Remove lamp. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 638 REMOVAL 1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument panel. Glove Box Lamp And Switch 3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle. INSTALLATION 1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 642 Hazard Warning Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 643 Hazard Warning Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR PROPER AND SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Battery Negative Cable 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch C1 Headlamp Switch C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 647 Headlamp Switch: Testing and Inspection Headlamp Switch Continuity Rheostat Continuity Headlamp Switch Connectors (Switch Side) Using a Digital Multimeter equipped with a diode test, perform the Headlamp Switch Continuity test and the Rheostat Continuity test. Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary. The Chrysler Town and Country is available with optional Automatic Headlamps. For diagnosis, refer to the proper Body Diagnostic Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch Headlamp Switch: Service and Repair Headlight Switch REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Headlamp Switch 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove screws holding the headlamp switch bezel to cluster bezel. 4. Disconnect the wire connectors from the headlamp switch and wire connector from the power mirror switch. 5. Remove headlamp switch bezel from cluster bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch > Page 650 Headlamp Switch: Service and Repair Headlight Switch Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. 3. Disconnect wire connectors. 4. Remove headlamp switch bezel from instrument cluster bezel. Headlamp Switch Lamp 5. Rotate bulb socket counterclockwise one quarter turn. 6. Pull bulb socket from headlamp switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Speed Control Switches Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 654 Horn Switch: Service and Repair REMOVAL AND INSTALLATION The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately. Refer to Passive Restraints for Driver Airbag Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 658 Turn Signal Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 659 Turn Signal Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation OPERATION The temperature sensor, in the PCM, is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 668 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 669 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 670 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 671 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 672 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 673 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 674 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Temperature Sensor 7 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 678 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 679 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 680 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 681 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40° F to 265° F). The engine coolant temperature sensor provides an input voltage to the PCM. As coolant temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle speeds until normal operating temperatures are reached. The engine coolant sensor is also used for cooling fan control. Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 682 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant Temperature Sensor 1. With the key off, disconnect wire harness connector from coolant temperature sensor. Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter should read as follows: a. ECT STET at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 683 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 687 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 688 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 689 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 690 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 691 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 692 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The level sensor is attached to the side of the fuel pump module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 696 Fuel Level Sensor: Description and Operation DESCRIPTION The level sensor is attached to the side of the fuel pump module. The level sensor consists of a float, an arm, and a variable resistor. OPERATION As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 697 Fuel Level Sensor: Testing and Inspection This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Level Sensor Diagnosis The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 698 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector. NOTE: The pump module harness on TOP of flange is not serviceable or removable. Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 699 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Level Sensor Removal/Installation 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 700 Groove In Back Side Of Level Sensor 2. Wrap wires into groove in back of level sensor. Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 704 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 705 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 706 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 707 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Sensor Tightening Torque 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 711 MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 712 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 713 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. MAP Sensor MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 714 MAP Sensor The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The sensor connects electrically to the PCM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 715 Manifold Pressure/Vacuum Sensor: Testing and Inspection To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. MAP Sensor Connector 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3. With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (± 0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If not OK, repair or replace the wire harness as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 716 Manifold Pressure/Vacuum Sensor: Service and Repair Map Absolute Pressure Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the intake manifold. INSTALLATION 1. Reverse the above procedure for installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Oxygen Sensor 27 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 722 Oxygen Sensor: Locations Oxygen Sensor(s) Heated Oxygen Sensor Downstream Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 723 Oxygen Sensor: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 724 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 725 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 726 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR Heated Oxygen Sensor Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 727 Heated Oxygen Sensor The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 728 Oxygen Sensor: Testing and Inspection Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical connector from each oxygen sensor. The white wires in the sensor connector are the power and ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement REMOVAL 1. Raise and support vehicle. WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. Oxygen Sensor Grommet Cover 2. Remove grommet cover to expose connector. Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector. Oxygen Sensor Removal/Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 731 INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 732 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Upstream Heated Oxygen Sensor The oxygen sensor is installed in the exhaust manifold . CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 736 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 737 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 738 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 739 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 740 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 745 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 746 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 747 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 748 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 749 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 750 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 751 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 757 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 760 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 761 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 762 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 765 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 768 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 770 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 774 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 775 Vehicle Speed Sensor: Description and Operation Description The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are threaded into the transaxle case and are considered primary inputs to the Trans- mission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 780 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 781 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 782 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 783 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 784 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 789 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 790 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 791 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 792 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 793 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 794 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 795 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 799 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 800 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 801 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 802 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 803 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 804 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 814 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 820 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 821 Ignition Switch Lock Cylinder: Description and Operation DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION Ignition Lock Cylinder Detents The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 822 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 823 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 827 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 828 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 829 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 830 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 836 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 837 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 838 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 839 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 840 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 841 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 842 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 843 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 844 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 845 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 846 PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 847 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 848 POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Instrument Panel Supports The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 852 Impact Sensor: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation OPERATION The temperature sensor, in the PCM, is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 869 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 875 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 876 Ignition Switch Lock Cylinder: Description and Operation DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION Ignition Lock Cylinder Detents The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 877 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 878 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 882 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Autostick/Overdrive Off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 888 Autostick/Overdrive Switch Connector Pin Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 892 Transmission Mode Switch: Diagrams For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 897 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 898 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 899 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 900 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 901 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 902 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 903 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 912 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 918 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 919 Transmission Speed Sensor: Specifications Speed Sensor Input 20 ft.lb Output 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 920 Input Speed Sensor/Output Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 923 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor Transmission Speed Sensor: Service and Repair Input Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 25 The input speed sensor is located to the left of the manual shift lever (Fig. 25). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 926 Transmission Speed Sensor: Service and Repair Output Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 26 The output speed sensor is located to the right of the manual shift lever (Fig. 26). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation SYSTEM OPERATION HVAC Control Panel/Rear Window Defogger Switch The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when the switch is activated. The switch energizes the timing circuit and activates the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection 1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or passenger side. Refer to Power Window Switch and Bezel Assembly Replacement. Power Window Master Switch Connector 2. Using an ohmmeter, Test driver door switch for continuity as described. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 3. Test passenger door switch for continuity as described. 4. If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down relay senses an amperage spike (motor pushing against down stop) in the feed circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike will cause the switch to disconnect after approximately 11 seconds. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 934 Power Window Switch: Service and Repair Window Switch and Bezel Replacement The Power Window Switch is integral to the bezel. If service to the switch is required, the complete bezel must be replaced. The Owe Door Lock Switch is serviced separately and must be transferred to the new bezel. REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Open door, remove screw cover near inside door release handle. 3. Remove two screws to Power Window Switch and Bezel Assembly One under the screw cover removed in previous step and one to the rear of the front door vent opening. 4. Pull out and up on bezel to release from door trim panel. 5. Disconnect two switch connectors. 6. Remove two door lock switch retaining screws and remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Fig.1 Wiper/Washer Switch Pin Call Out Windshield Wiper and Washer / Multi-function Switch Test 2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper and Washer / Multi-function Switch Test table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 942 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Turn Signal and Flashers, for Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch Wiper Switch: Testing and Inspection Failed Park Switch If the wiper park switch has failed the windshield wipers will operate as follows: SWITCH OFF Wipers stop in current location regardless of the park signal. INTERMITTENT MODE - Wipers operate at low speed for one or more extra wipes or continuously. LOW SPEED - Wipers operate at low speed. HIGH SPEED - Wipers operate at high speed. PULSE WIPE - Wipers will not operate. WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate only while wash button is depressed with switch in OFF mode, wipers stop in mid-cycle when button is released. Wiper System Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 948 Wiper System Diagnosis (Part 2 Of 2) The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit can be tested using the Wiper System Diagnosis table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 949 Wiper Switch: Testing and Inspection Wiper Switch Test To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Fig.1 Wiper/Washer Switch Pin Call Out Windshield Wiper and Washer / Multi-function Switch Test 2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper and Washer / Multi-function Switch Test table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 950 Wiper Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Turn Signal and Flashers, for Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine NOTES: - All specifications are given in degrees. - All wheel alignments are to be set at curb height. FRONT: Camber (All Vehicles Except Those With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17): Preferred Setting ................................................................................................................................. ..................................................................... +0.15° Acceptable Range .............................................. ........................................................................................................................................ -0.25 to +0.55° Camber (Vehicles With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17): Preferred Setting .. .............................................................................................................................................................. ...................................... +0.05° Acceptable Range ............................................................................. ......................................................................................................... -0.25 to +0.55° Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ............................................... ......................................................................................................................................................... +0.0° Acceptable Range ...................................................................................................................... ................................................................................ 0.50° Caster [1]: Preferred Setting ................................................................................................................ ...................................................................................... +1.40° Acceptable Range ............................. ....................................................................................................................................................... +0.40° to +2.40° Cross Caster (Maximum Side-to-Side Difference): Preferred Setting ................................................. ......................................................................................................................................................... 0.0° Acceptable Range ........................................................................................................................ .............................................................................. 1.00° Total Toe [2]: Preferred Setting ........................................................................................................... ........................................................................................... +0.10° Acceptable Range ........................ ............................................................................................................................................................. -0.10° to +0.30° Total Toe (Maximum Side-to-Side Difference): Preferred Setting ....................................................... ................................................................................................................................................... 0.0° Acceptable Range ............................................................................................................................... ....................................................................... 0.06° Curb Height: Standard ......................................................................................................................................................... 783.5 mm ±10 mm (30.85 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) REAR: Camber [1]: Preferred Setting .............................................................................................................. ......................................................................................... -0.10° Acceptable Range .......................... ............................................................................................................................................................ -0.35 to +0.15° Total Toe [1, 2]: Preferred Setting ....................................................................................................... ................................................................................................... 0.0° Acceptable Range .................... .............................................................................................................................................................. ... -0.40° to +0.40° Thrust Angle [1]: Preferred Setting ...................................................................................................... .................................................................................................... 0.0° Acceptable Range ................... .............................................................................................................................................................. .... -0.30° to +0.30° Curb Height: Standard ......................................................................................................................................................... 802.5 mm ±10 mm (31.59 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) [1] For reference only. These are non-adjustable angles. [2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 956 Alignment: Specifications All Except W/Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17 NOTES: - All specifications are given in degrees. - All wheel alignments are to be set at curb height. FRONT: Camber: Preferred Setting ................................................................................................................... ................................................................................... +0.15° Acceptable Range ................................ ...................................................................................................................................................... -0.25 to +0.55° Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ............................................... ......................................................................................................................................................... +0.0° Acceptable Range ...................................................................................................................... ................................................................................ 0.50° Caster [1]: Preferred Setting ................................................................................................................ ...................................................................................... +1.40° Acceptable Range ............................. ....................................................................................................................................................... +0.40° to +2.40° Cross Caster (Maximum Side-to-Side Difference): Preferred Setting ................................................. ......................................................................................................................................................... 0.0° Acceptable Range ........................................................................................................................ .............................................................................. 1.00° Total Toe [2]: Preferred Setting ........................................................................................................... ........................................................................................... +0.10° Acceptable Range ........................ ............................................................................................................................................................. -0.10° to +0.30° Total Toe (Maximum Side-to-Side Difference): Preferred Setting ....................................................... ................................................................................................................................................... 0.0° Acceptable Range ............................................................................................................................... ....................................................................... 0.06° Curb Height: Standard ......................................................................................................................................................... 747.5 mm ±10 mm (29.43 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) REAR: Camber [1]: Preferred Setting .............................................................................................................. ............................................................................................ 0.0° Acceptable Range ........................... ........................................................................................................................................................... -0.25 to +0.25° Total Toe [1, 2]: Preferred Setting ....................................................................................................... ................................................................................................... 0.0° Acceptable Range .................... .............................................................................................................................................................. ... -0.40° to +0.40° Thrust Angle [1]: Preferred Setting ...................................................................................................... .................................................................................................... 0.0° Acceptable Range ................... .............................................................................................................................................................. .... -0.30° to +0.30° Curb Height: Standard ......................................................................................................................................................... 766.0 mm ±10 mm (30.15 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) [1] For reference only. These are non-adjustable angles. [2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 957 Alignment: Specifications With Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17 NOTES: - All specifications are given in degrees. - All wheel alignments are to be set at curb height. FRONT: Camber: Preferred Setting ................................................................................................................... ................................................................................... +0.05° Acceptable Range ................................ ...................................................................................................................................................... -0.35 to +0.45° Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ............................................... ......................................................................................................................................................... +0.0° Acceptable Range ...................................................................................................................... ................................................................................ 0.50° Caster [1]: Preferred Setting ................................................................................................................ ...................................................................................... +1.40° Acceptable Range ............................. ....................................................................................................................................................... +0.40° to +2.40° Cross Caster (Maximum Side-to-Side Difference): Preferred Setting ................................................. ......................................................................................................................................................... 0.0° Acceptable Range ........................................................................................................................ .............................................................................. 1.00° Total Toe [2]: Preferred Setting ........................................................................................................... ........................................................................................... +0.10° Acceptable Range ........................ ............................................................................................................................................................. -0.10° to +0.30° Total Toe (Maximum Side-to-Side Difference): Preferred Setting ....................................................... ................................................................................................................................................... 0.0° Acceptable Range ............................................................................................................................... ....................................................................... 0.06° Curb Height: Standard ......................................................................................................................................................... 753.5 mm ±10 mm (29.66 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) REAR: Camber [1]: Preferred Setting .............................................................................................................. ............................................................................................ 0.0° Acceptable Range ........................... ........................................................................................................................................................... -0.25 to +0.25° Total Toe [1, 2]: Preferred Setting ....................................................................................................... ................................................................................................... 0.0° Acceptable Range .................... .............................................................................................................................................................. ... -0.40° to +0.40° Thrust Angle [1]: Preferred Setting ...................................................................................................... .................................................................................................... 0.0° Acceptable Range ................... .............................................................................................................................................................. .... -0.30° to +0.30° Curb Height: Standard ......................................................................................................................................................... 772.0 mm ±10 mm (30.39 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) [1] For reference only. These are non-adjustable angles. [2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 958 Alignment: Description and Operation Vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension angles. These angles are what effects the handling and steering of the vehicle when it is in motion. The method of checking a vehicle's front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the equipment being used should always be followed to ensure accuracy of the alignment, except when alignment specifications recommended by Chrysler Corporation differ. Typical wheel alignment angles and measurements are camber, caster, toe, and thrust angle. Alignment Camber And Toe - Camber is the number of degrees the top of the tire and wheel are tilted either inward or outward. Camber is a tire wearing angle. Excessive negative camber will cause tread wear at the inside of the tire, while excessive positive camber will cause outside tire wear. - Caster is the number of degrees of forward or rearward tilt of the steering knuckle. Forward tilt provides a negative caster angle, while rearward tilt provides a positive caster angle. Caster is not adjustable on this vehicle. - Cross camber is the difference between left and right camber. The right side camber is to be subtracted from the left, resulting in the cross camber reading. For example, if the left camber is +0.3° and the right camber is 0.0°, the cross camber would be +0.3°. - Toe is measured in degrees or inches and is the difference in width between the centered leading and trailing edges of the tires on the same axle. Toe-in means that the front width is more narrow than the rear. Toe-out means that the front width is wider than the rear. - Thrust angle is defined as the average of the toe settings on each rear wheel. If this measurement is out of specification, readjust the rear wheel toe so that each wheel has 1/2 of the total toe measurement. When readjusting, do not exceed the total toe specification. Wheel alignment on this vehicle is to be checked and all alignment adjustments made with the vehicle at its curb height specification. Curb height is the riding height of the vehicle measured from a certain point on the vehicle to the ground while the vehicle is setting on a flat, level surface. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 959 Alignment: Testing and Inspection PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. If curb height is out of specifications, check for broken or sagged springs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height Measurement Alignment: Service and Repair Curb Height Measurement The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, the maximum left-to-right differential is not to exceed 12.5 mm (0.5 inch). 3. Compare the measurements to the specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 962 Alignment: Service and Repair Wheel Alignment 1. Position the vehicle on an alignment rack. 2. Perform the PRE-WHEEL ALIGNMENT INSPECTION. 3. Install all required alignment equipment on the vehicle per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 4. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. 5. If front camber and caster are not within specifications, proceed to CAMBER AND CASTER below. If caster and camber are within specifications, proceed to TOE which can be found following CAMBER AND CASTER. Rear camber, caster and toe are not adjustable. If found not to be within specifications, reinspect for damaged suspension or body components and replace as necessary. CAMBER AND CASTER Camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as NET BUILD. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles. Camber and caster should be checked to ensure they meet vehicle specifications. If front camber is found not to meet alignment specifications, it can be adjusted using an available camber adjustment bolt package. Before installing a camber adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension components for any signs of damage or bending. CAUTION: Do not attempt to adjust the vehicles wheel; alignment by heating, bending or by performing any other modification to the vehicle's front suspension components or body. If camber readings are not within specifications, use the following procedure to install the front camber adjustment bolt package and then adjust front camber. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains 2 flange bolts, 2 cam bolts, 2 dog bone washers, and 4 nuts. This package services both sides of the vehicle. Use the package to attach the strut clevis bracket to the steering knuckle after the strut clevis bracket has been modified. To install and adjust the camber adjustment bolt package, follow the procedure below. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. 2. Remove the front tire and wheel assemblies. CAUTION: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to support the steering knuckle assembly or if required remove the brake flex hose from the caliper assembly. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. Clevis Bracket To Steering Knuckle Attaching Bolts 3. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard. Separate the steering knuckle from the strut clevis bracket and position steering knuckle so it is out of the way of the strut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 963 Strut Clevis Bracket Bolt Hole Grinding Area CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the hole beyond the indentations on the sides of the strut clevis bracket. 4. Using an appropriate grinder and grinding wheel, slot the bottom hole in both sides of the strut clevis bracket. CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog bone washers from the service package must be used to attach the steering knuckle to the strut after the mounting hole is slotted. Package Bolts Correctly Installed (left Shown) 5. Position the knuckle back into the strut clevis bracket. Install a flanged bolt from the service package into the upper mounting hole. Install a cam bolt into the bottom mounting hole. Both bolts should point forward once installed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 964 Dog Bone Washer And Nuts Installed On Attaching Bolts 6. Install a dog bone washer on the steering knuckle to strut clevis bracket attaching bolts, then install the nuts onto the bolts from the service package. Tighten the bolts just enough to hold the steering knuckle in position when adjusting camber, while still allowing the steering knuckle to move in clevis bracket. 7. Repeat the procedure to the other side strut clevis bracket. 8. Reinstall both front tire and wheel assemblies and tighten to specifications. 9. Lower the vehicle. Jounce the front and rear of vehicle an equal amount of times. Camber Adjustment Cam Bolt 10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket. When camber is set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce front and rear of vehicle an equal amount of times and verify front camber setting. Torque both front strut to steering knuckle attaching bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4 turn after the required torque is met. 11. If toe readings obtained are not within the required specification range, adjust toe to meet the preferred specification setting. Toe is adjustable using the following procedure. TOE 1. Center the steering wheel and lock in place using a steering wheel clamp. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 965 Front Wheel Toe Adjustment 2. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front toe to the preferred toe specification. 3. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 4. Adjust steering gear to tie rod boots at the inner tie rod. 5. Remove steering wheel clamp. 6. Remove the alignment equipment. 7. Road test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Key On, Engine Off .............................................................................................................................. ......................................... (approx.) 338 kPa (49 psi) Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 971 Fuel Pressure: Capacity Specifications Information not supplied by the manufacturer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 975 Idle Speed: Testing and Inspection 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. PCV Valve 4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6. Air Metering Fitting 6457 a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b. Disconnect the idle purge line from the throttle body nipple. 7. a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector. 8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 10. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum air-flow is set correctly. IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above 1000 Miles = 575-875 RPM 12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 976 b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle purge line. 16. Remove DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Air Inlet Resonator 1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves together. Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 981 Air Cleaner Element 4. Remove element from air cleaner housing. INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 986 Fuel Pressure Release: Service and Repair WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. Fuel Pressure Test Port Releasing Fuel Pressure 3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. 5. Replace Pressure test port cap when finished doing pressure test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable = Maximum Resistance #1 = 18.5 K Ohms #2 = 15.5 K Ohms #3 = 20.4 K Ohms #4 = 21.2 K Ohms #5 = 27.7 K Ohms #6 = 26.7 K Ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 997 Ignition Cable: Description and Operation DESCRIPTION The spark plug cables and spark plug boots are made from high temperature silicon materials. The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. They also identify proper heat shield installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The bottom of the spark plug heat shield must make contact with the spark plug hex. The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 998 Ignition Cable: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. Spark Plug Cables # 3 And # 5 REMOVAL 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 3. Remove the cable from the retaining bracket. Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. Spark Plug Cable # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove the cable from the retaining bracket. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1002 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1003 Spark Plug: Description and Operation SPARK PLUGS RESISTER DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Setting Spark Plug Electrode Gap Refer to the Specifications for gap and type of spark plug. SPARK PLUGS PLATINUM DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule. All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads The spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions per schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both electrode ends as shown. Extreme care must be used to prevent spark plug cross threading, mis-gaping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1004 Spark Plug: Testing and Inspection Spark Plug Condition Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Normal Operating Conditions Normal Operation And Cold (Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and then reinstalled. CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones. Oil Or Ash Encrusted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1005 Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Electrode Gap Bridging Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Scavenger Deposits Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1006 Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. Spark plugs with chipped electrode insulators must be replaced. Preignition Damage Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1007 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1008 Spark Plug: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation Use extreme care when removing and installing the spark plug cables. The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly Spark Plug # 3 AND # 5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator]ator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. Spark Plug # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure: Minimum 100 psi with no more than 25% variance between cylinders. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1012 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators: fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System, disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. Refer to Powertrain Management for Specifications. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1024 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1029 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1030 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1031 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1037 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1042 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1043 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1044 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1045 Accessory Drive Belt-3.3/3.8L Engines Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1046 Drive Belt: Description and Operation The accessory drive system utilizes two different style of drive belts. The conventional V-belt and the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump and water pump. Satisfactory performance of these belts depends on belt condition and proper belt tension. Belt tensioning should be performed with the aid of a Belt Tension Gauge, Special Tool 7198. Because of space limitations in the engine compartment, the use of this gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the drive belts, if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1047 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1048 Drive Belt: Adjustments Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning should be performed with the aid of Special Tool 7198. Because of space limitations in the engine compartment, the use of this gauge may be restricted. Raise the vehicle on a hoist and the remove the splash shield to gain access to the drive belts, if necessary. BELT TENSION GAUGE METHOD Use belt tension gauge, Special Tool 7198. Adjust belt tension for either a New or Used belt. For specifications, refer to Belt Tension Chart. BELT TENSION CHART Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation A/C Belt Refer to Drive Belt, Alternator for procedure. Alternator Belt Accessory Drive Belt-3.3/3.8L Engines The Poly-V serpentine drive belt is provided with a dynamic tensioner to maintain proper belt tension to drive the following components: ^ generator ^ power steering pump ^ air conditioning compressor ^ water pump REMOVAL 1. Raise vehicle on hoist. Accessory Drive Belt Splash Shield 2. Remove accessory drive belt splash shield. WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO TENSIONER AND/OR PERSONAL INJURY COULD RESULT. 3. Release belt tension by rotating the tensioner clockwise. 4. Remove drive belt. INSTALLATION 1. Properly route and position belt onto all pulleys, except for the tensioner pulley. 2. Rotate belt tensioner clockwise until belt can be installed onto the tensioner pulley. Slowly release belt tensioner. 3. Verify belt is properly routed and engaged on all pulleys. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1051 4. Install splash shield and lower vehicle. Power Steering Belt Refer to Drive Belt, Alternator for procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1052 Drive Belt: Service and Repair Cleaning and Inspection Serpentine Drive Belt Wear Patterns When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks running along the rib (not across) are not normal. Any belt with cracks running along the rib must be replaced. Also replace the belt if it has excessive wear, frayed cords, or severe glazing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Page 1053 Belt Tension Gauge 7198 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Air Inlet Resonator 1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves together. Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1059 Air Cleaner Element 4. Remove element from air cleaner housing. INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation OPERATION All engines use filtered air to vent the crankcase. The filtered air is drawn through the resonator assembly located between the air cleaner and throttle body. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. Fig. 8 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. TRANSMISSION FLUID TEMPERATURE CHART Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1066 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening ALTERNATIVE SERVICE METHODS (FLUID ONLY) TRANSAXLE FLUID EXCHANGER METHOD CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not recommended. 1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive the vehicle until it reaches full operating temperature. 2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the vehicle following the manufacturers instructions. Perform the exchange procedure following the instructions provided with the machine. 5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to proper level with MOPAR ATF+4 Type 9602. Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure. NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line torque specification is 2 Nm (18 inch lbs.). DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1071 Fuel Pressure Release: Service and Repair WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. Fuel Pressure Test Port Releasing Fuel Pressure 3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. 5. Replace Pressure test port cap when finished doing pressure test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Inlet Strainer Removal 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer. 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Bypass Valve Setting 9 - 15 psi Oil Filter Type Full Flow Oil Pressure Switch Actuating Pressure (Min.) 2 - 4 psi Oil Filter Attaching Nipple 30 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1078 Oil Filter: Service and Repair Oil Filter CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using suitable oil filter wrench, turn filter counterclockwise to remove from base. Properly discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft. lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair Refrigerant Filter: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION . 1. Recover A/C system refrigerant. Filter-Drier Assembly 2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location. INSTALLATION 1. Before installation , replace both refrigerant line O-rings. Then reverse the above procedures. Torque filter/drier mounting bolts to 45 in. lbs. ± 10. 2. Evacuate and recharge system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Upper Heater Hose Lower Heater Hose 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C Suction/Discharge Line - Service Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service NUMBER: 24-14-99 GROUP: Heating & A/C DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Suction And/Or Discharge Line Service MODELS: 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are torqued to 40 ft. lbs. (54 Nm). The root cause of A/C suction and/or discharge line cracking at or near the compressor may be related to the compressor being improperly secured to the engine. Excessive vibration may result if the compressor attaching bolts are not properly torqued. This vibration will eventually crack the aluminum tubing of the A/C lines and/or compressor mounting ears. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Recover A/C system refrigerant. Compressor Discharge Line 2. Remove discharge line mounting nut at compressor. Condenser Discharge Line 3. Remove discharge line at the top fitting on the condenser. INSTALLATION 1. For installation , reverse the above procedures. Replace all O-rings. Torque discharge line at condenser bolt to 180 in. lbs. ± 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC Control Calibration Diagnostic and Cooldown test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1092 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9. Cover the openings to prevent contamination. 10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. It may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece assembly. 13. Remove the old O-rings. INSTALLATION For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1093 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve. Suction Line At Compressor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1094 9. Remove suction line mounting nut at compressor. 10. Remove suction line mounting bracket. 11. Remove suction line. INSTALLATION For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1095 Hose/Line HVAC: Service and Repair Refrigerant Line Replacement Rear Air Conditioning Lines WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Hoist vehicle Front Lines Connected To Rear Lines 2. Remove compression fittings to the suction and liquid lines located on the right, outboard side of the underbody, rearward of the front crossmember. Rear A/C Block Connection 3. Remove (1) bolt securing A/C lines to block located on the right, outboard side of the underbody, rearward of the rear wheel and tire. Rear Heater And A/C Lines Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1096 4. Remove (3) straps securing underbody lines. 5. Separate and remove A/C lines from vehicle. INSTALLATION 1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved wax-free refrigerant oil. Then, reverse the above procedures. 2. Evacuate and recharge system. Rear Heater Lines REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Partially drain engine cooling system. Front Lines Connected To Rear Lines 2. Loosen clamp at the front end of the hose located at the right, outboard side of the underbody, rearward of the front crossmember. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. CAUTION: When removing hoses from outlet nipples, do not use excessive force. Outlet nipples may become damaged and leak engine coolant. Rear Heater Hose Quick Connects 4. Compress insert in rear heater hose quick connection and pull downward on hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1097 Rear Heater And A/C Lines 5. Remove (3) straps securing underbody lines. 6. Separate and remove rear heater lines from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1106 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1107 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1108 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1109 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1110 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1111 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1117 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1118 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1119 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1120 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1121 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1122 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1123 Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ................................................ 31 Nm (275 inch lbs.) Routing Bracket To Suspension Cradle .................................................................................................................................................... 28 Nm (21 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1124 Power Steering Line/Hose: Description and Operation Power Steering Hoses The power steering fluid hoses connect the components of the power steering system. They transfer fluid from one component to the next. The power steering fluid supply hose is a formed hose that connects the power steering fluid reservoir to the power steering pump. It is secured at both ends using standard adjustable clamps. The power steering fluid pressure hose is a high pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting with an O-ring is used at both ends to connect the components. The power steering fluid return hose is a formed metal and rubber hose that connects the gear back to the power steering pump. A standard tube nut fitting with an O-ring is used to connect it to the gear. It is secured to the power steering pump using a standard adjustable clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump REMOVE Fluid Supply Hose At Power Steering Fluid Reservoir 1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. Power Steering Fluid Hose Routing Clip 3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the power steering fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain out of the reservoir and hose. 6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle. Hose is removed from the top of the engine compartment. INSTALL CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube. This routing will prevent the power steering fluid supply hose from coming in contact with the accessory drive belt. 1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on fluid reservoir fitting. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on pump fitting. 5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is installed in a position to correctly align with stud in strut tower. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1127 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper level and let the fluid settle for at least two minutes. 9. Start the engine and let run for a few seconds. Then turn the engine off. 10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1128 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. For part reference and part location for the vehicle that is being serviced, refer to the illustrations. These show the hose bracket locations, hose routings and fitting locations by the engine application of the vehicle. Use these images when referring to the removal or installation procedures for the power steering hoses listed below. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel tube connection. Remove the hose clamp from the power steering fluid return hose. Remove power steering fluid return hose from steel tube and allow power steering fluid to drain from pump. Pressure Hose Connection To Power Steering Pump 5. Remove the power steering fluid pressure line from the power steering pump pressure fitting. Drain excess power steering fluid from hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1129 6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle. 7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid pressure hose. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power steering pressure hose to the fittings on the power steering pump and steering gear. Route hose avoiding tight bends or kinking. Do not bend tube ends of the power steering hoses when installing. 4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces of the vehicle. CAUTION: When tightening and torquing the pressure hose at the power steering pump, the pressure hose is to be rotated against the fluid return hose fitting on the pump. 5. Tighten all fasteners shown for specific applications to their correct torques listed below: - Pump End Tube Nut 34 Nm (25 ft. lbs.) - Gear End Tube Nut 34 Nm (25 ft. lbs.) - Pump Bracket Nut 40 Nm (30 ft. lbs.) 6. Install the power steering fluid return hose on the steel tube at the front suspension cradle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1130 7. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch. lbs.). CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. 8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 9. After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1131 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. For part reference and part location for the vehicle that is being serviced, refer to the images. These show the hose bracket locations, hose routings and fitting locations by the engine application of the vehicle. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube connection. Remove hose clamp where rubber portion of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber hose from steel tube and allow power steering fluid to drain from pump. 5. Remove the power steering fluid return hose from the power steering pump return hose fitting. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route hose smoothly avoiding tight bends or kinking. Hose must remain away from the exhaust system and not come in contact with any unfriendly surfaces of the vehicle. 3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch. lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is to prevent overheating of the power steering fluid hoses. 5. When used, position the protective heat sleeves on the power steering hoses so they cover the connection to the power steering pump. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 6. After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Spring Clamp Size Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. Hose Clamp Tool The hose clamps are removed by using Special Tool 6094 or equivalent constant tension clamp pliers to compress hose clamp. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. Make sure hoses and connectors are clean and dry before installation. Do not lubricate hoses when installing. Spring type hose clamps are used in all applications. If replacement is necessary, replace with the original Mopar(R) equipment spring type clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1139 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact-rinse eyes thoroughly with water. * Skin Contact-wash skin with soap and water. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1140 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1141 Brake Fluid: Service and Repair MASTER CYLINDER FLUID LEVEL CHECK Check master cylinder reservoir fluid level a minimum of twice annually. Master Cylinder Fluid Level Marks Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid fill level of the master cylinder. If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of the fluid reservoir with brake fluid. Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. Do not use brake fluid with a lower boiling point, as brake failure could result during prolonged hard braking. Use only brake fluid that was stored in a tightly sealed container. Do not use petroleum-based fluid because seal damage will result. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid etc. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY 2.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 10.6 L (11.23 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .................................................................. N/A Rear Heater ............................................................... ............................................................................................................................................. N/A 3.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ........................................................................................................................ 15.0 L (15.9 qts) 3.3/3.8L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) Trailer Tow Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) NOTE: Capacities include heater and coolant recovery tank filled to Max level. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1146 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1147 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description and Operation Coolant: Description and Operation The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the radiator, where the tube/fin assemblies of these components can give it up to the air. The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar(R) Antifreeze or the equivalent is recommended for best engine cooling without corrosion, when mixed only to a freeze point of -37°C (-35°F) to -5C (-50F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description and Operation > Page 1150 Coolant: Description and Operation Coolant Performance Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for each degree of temperature rise for each pound of water). This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: ^ Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). ^ 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point to -22°C (-8°F). ^ 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, sending unit and heater are all designed for 50/50 glycol. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -59°C (-50°F). CAUTION: Richer mixtures cannot be measured with field equipment. This can lead to problems associated with 100 percent glycol. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1151 Coolant: Testing and Inspection Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, Rush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -59°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. Hydrometers test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 70% by volume glycol). Refractometers test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is only recommended for limited usage. Refer to appropriate Technical Service Bulletin(s) regarding use of propylene glycol based coolants. CAUTION: Do not mix types of coolant. Corrosion protection will be severely reduced. Because ethylene glycol and propylene glycol do not have the same specific gravities, the use of a hydrometer will be inaccurate. Therefore, Special Tool 8286 refractometer, must be used when testing coolant. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1152 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 1157 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 1158 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 31TH .................................................................................................................................................... ............................................................. 8.0L (8.5 Qt) 41TE ................................................................. ................................................................................................................................................ 8.6L (9.1 Qt) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1161 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1162 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check NOTE: The transmission and differential utilize the same fluid sump, which require Automatic Transmission Fluid (ATF+4/Type 9602). NOTE: The transmission fluid level should be inspected at least every six months. FLUID LEVEL CHECK The transmission sump has a dipstick to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fig. 7 The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C or 180°F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator (Fig. 7). The fluid level will be approximately one-quarter inch above the lower hole of the dipstick at 70°F fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRBIII scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. 5. Compare the fluid temperature value with the chart. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1165 TRANSMISSION FLUID TEMPERATURE CHART 6. Adjust transmission fluid level shown on the dipstick according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1166 Fluid - A/T: Service and Repair Fluid and Filter Service NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. Fig. 8 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. TRANSMISSION FLUID TEMPERATURE CHART Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1167 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening ALTERNATIVE SERVICE METHODS (FLUID ONLY) TRANSAXLE FLUID EXCHANGER METHOD CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not recommended. 1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive the vehicle until it reaches full operating temperature. 2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the vehicle following the manufacturers instructions. Perform the exchange procedure following the instructions provided with the machine. 5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to proper level with MOPAR ATF+4 Type 9602. Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure. NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line torque specification is 2 Nm (18 inch lbs.). DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Capacity ............................................................................................................................................... ......................................................... 1.9L (4.0 Pints) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1172 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1173 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Power Transfer Unit ............................................................................................................................. ........................................................ 1.2L (2.4 Pints) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1178 Fluid - Transfer Case: Fluid Type Specifications Power Transfer Unit Viscosity .............................................................................................................................................. .............................................................. SAE 85W-90 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1179 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 3.8L (4.0 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1184 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1185 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1190 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1191 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1192 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid 1.7 pt (US) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1195 Power Steering Fluid: Fluid Type Specifications All models Mopar Power Steering Fluid or equivalent Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1196 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1197 Power Steering Fluid: Service and Repair WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. CAUTION: Do not use automatic transmission fluid in the power steering system. Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. The dipstick should indicate COLD when the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). Do not overfill the power steering system. Use only Mopar Power Steering Fluid, or an equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................ ........................................ 0.96 kg (34 oz. or 2.13 lbs) R134a Dual Capacity ........................................................................................................................... ....................................... 1.36 kg (48 oz. or 3.00 lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1202 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1203 Refrigerant: Description and Operation This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge and/or poor performance. Never add any other type of refrigerant to a system designed to use R-134a refrigerant. System failure will occur. The high pressure service port is located on the liquid line near the strut tower. The low pressure service port is located on the suction line near the compressor manifold. Refrigerant Recovery/Recycling Station (Typical) When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Manifold Gauge Set - Typical A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the oil that is specified on the under hood label. Due to the different characteristics of R-134a it requires all new service procedures. The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and low global warming impact. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Front A/C Compressor ......................................................................................................................... ............................................................ 150 ml 5.0 oz. Dual A/C Compressor .......................................................................................................................... ............................................................ 220 ml 7.4 oz. Dual A/C Evaporator ............................................................................................................................ .............................................................. 60 ml 2.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1208 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1209 Refrigerant Oil: Service and Repair Refrigerant Oil Level Check Refrigerant Oil Capacities When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. when a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (6.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add system capacity minus the capacity of components that have not been replaced through suction port on compressor. Refer to the Refrigerant Oil Capacity Chart. 6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures Bleeding Base Brake Hydraulic System NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake System bleeding procedure in antilock brakes. Pressure Bleeding Procedure CAUTION: - Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. - Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the hydraulic system for bleeding. - When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system is pressurized. Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment. Air Trapped In Brake System When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. 1. Remove the filler neck from the master cylinder fluid reservoir. Pressure Bleeding Cap Installed On Master Cylinder 2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the fluid reservoir of the master cylinder. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent. 3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 1214 adequate removal of all trapped air from the brake hydraulic system. (1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel Rear Wheel Cylinder Bleeder Screw 4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid discharge will NOT get all the air out. 5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Bleeding Without A Pressure Bleeder NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are correctly adjusted. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 1215 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brake hydraulic system, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure or standard pressure bleeding equipment. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRB. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Base Brake Bleeding. 5. Using the DRB, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1220 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to diagnose the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations For fuse location and identification, refer to Electrical Accessory Panel (Power Distribution Center) and/or Fuse Block (Junction Block) Locations, Components. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1225 Fuse: Diagrams Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1226 Junction Block Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1227 Power Distribution Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1228 Power Distribution Center Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Fuse Block: Connector Views Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Junction Block C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Junction Block C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Junction Block C3 (D) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Junction Block C4 (C) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 Fuse Block: Electrical Diagrams Except Chrysler Junction Block -- Sheet 8w-12-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 Junction Block -- Sheet 8w-12-9 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Junction Block -- Sheet 8w-12-10 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 Junction Block -- Sheet 8w-12-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Junction Block -- Sheet 8w-12-12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 Junction Block -- Sheet 8w-12-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 Junction Block -- Sheet 8w-12-14 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 Junction Block -- Sheet 8w-12-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 Junction Block -- Sheet 8w-12-16 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 Junction Block -- Sheet 8w-12-17 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 Junction Block -- Sheet 8w-12-18 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 Junction Block -- Sheet 8w-12-19 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 Junction Block -- Sheet 8w-12-20 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 Junction Block -- Sheet 8w-12-21 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 Junction Block -- Sheet 8w-12-22 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 Junction Block -- Sheet 8w-12-23 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 Junction Block -- Sheet 8w-12-24 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation This vehicle does not have a Maintenance Reminder Light option. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR (CHECK ENGINE) LAMP-PCM OUTPUT The PCM supplies the malfunction indicator (check engine) lamp on/off signal to the instrument panel through the CCD Bus. The CCD Bus is a communications port. Various modules use the CCD Bus to exchange information. The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3 seconds as a bulb test. The Malfunction Indicator Lamp (MIL) stays on continuously, when the PCM has entered a Limp-In mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM compensates for the failure of certain components that send incorrect signals. The PCM substitutes for the incorrect signals with inputs from other sensors. If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the MIL. At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger the MIL (Check Engine Lamp) refer to the On-Board Diagnostics Chart. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 1285 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Testing and Inspection Oil Level Warning Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Spare Tire - Winch Precautions Spare Tire: Technical Service Bulletins Spare Tire - Winch Precautions BULLETIN NUMBER: 22-01-00 GROUP: Wheels & Tires DATE: Mar.24, 2000 SUBJECT: Spare Tire Winches MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN DOES NOT APPLY TO 1999 TOWN & COUNTRY VEHICLES BUILT PRIOR TO JULY 2, 1998. DISCUSSION: Beginning November 1,1999, the spare tire winch that is installed during vehicle assembly is determined by the size/type of spare tire the vehicle is built with. DO NOT switch the size/type of spare tire a vehicle is equipped with unless the spare tire winch is the correct one for the size/type of spare tire to be used. Replacement of the spare tire winch may be required. The spare tire winches are equipped with a secondary locking mechanism that may not function properly if a full size spare or T125 70D15 Compact Spare is stored on a T145 90D16 compact spare winch or vise-versa. The illustration shows the correct application and identification for 1999-2000 NS-vehicle spare tire winches: PARTS INFORMATION CAUTION: DO NOT SWITCH THE SIZE/TYPE OF SPARE TIRE A VEHICLE IS EQUIPPED WITH UNLESS THE SPARE TIRE WINCH IS CORRECT FOR THE NEW SIZE/TYPE OF SPARE TIRE AS CALLED OUT IN THE TABLE ABOVE. REPLACEMENT OF THE SPARE TIRE WINCH MAY BE REQUIRED. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 1295 Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1304 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1305 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1306 TIRE/WHEEL MATCH MOUNTING Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1307 WHEEL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1308 WHEEL BORE PILOT DIAMETERS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1309 HUB WHEEL PILOT DIAMETER Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1310 HUB WHEEL PILOT RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1311 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1317 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1318 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1319 TIRE/WHEEL MATCH MOUNTING Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1320 WHEEL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1321 WHEEL BORE PILOT DIAMETERS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1322 HUB WHEEL PILOT DIAMETER Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1323 HUB WHEEL PILOT RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1324 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance Weights Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights NO: 22-01-98 GROUP: Tires & Wheels DATE: Mar. 13, 1998 SUBJECT: Balance Weights For Aluminum Wheels MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town & Country/Caravan/Voyager DISCUSSION: Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance weight retention flange. This balance weight retention flange requires the use of special low profile balance weights. The new balance weights are made by Perfect Equipment Company LLC, and are available through their distributors and subsequent automotive jobbers. The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors listed: POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance Weights Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights NO: 22-01-98 GROUP: Tires & Wheels DATE: Mar. 13, 1998 SUBJECT: Balance Weights For Aluminum Wheels MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town & Country/Caravan/Voyager DISCUSSION: Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance weight retention flange. This balance weight retention flange requires the use of special low profile balance weights. The new balance weights are made by Perfect Equipment Company LLC, and are available through their distributors and subsequent automotive jobbers. The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors listed: POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1334 Wheels: Description and Operation Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for the specific wheel applications used on a vehicle and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design from the original equipment part. All aluminum wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Vehicles that are equipped with bolt-on wheel covers use large nose wheel nuts. The wheel nuts used on a vehicle equipped with bolt-on wheel covers are externally threaded so that the wheel covers can be attached to the wheel nuts. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. WARNING: INSTALLING WHEELS WITHOUT GOOD METAL-TO-METAL CONTACT COULD CAUSE LOOSENING OF WHEEL LUG NUTS. THIS COULD ADVERSELY AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1335 Wheels: Testing and Inspection Wheels must be replaced if they: Have excessive run out - Are bent, dented or cracked - Leak air - Have damaged wheel lug holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels are available through the dealer. When obtaining replacement wheels from any other source, they must be equivalent in load carrying capacity. The wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match the original equipment wheels. WARNING: FAILURE TO USE ORIGINAL EQUIPMENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE. - REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY OF THE RIM MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1347 Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque .................................................................................................................................... ................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ........................................................... ........................................................................................................................................................... 19 mm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1348 Wheel Fastener: Specifications Wheel Stud Size Mounting Stud Size ............................................................................................................................. ........................................................... M12 x 1.5 mm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front REMOVAL CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CANNOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. The following procedure and special tools shown MUST BE used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. Disc Brake Caliper Mounting 3. Remove the front caliper assembly from the front steering knuckle assembly. 4. Remove front rotor from hub, by pulling it straight off wheel mounting studs. 5. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly, so the threads on the stud are even with end of lug nut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1351 Wheel Stud Removal From Hub/Bearing Assembly Install Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud. 6. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. When shoulder of wheel stud is past flange remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel stud from flange. INSTALLATION Installing Wheel Stud Into Hub And Bearing 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back over braking disc and align with caliper mounting holes on steering knuckle. Install the caliper adapter to steering knuckle attaching bolts and torque to 19 Nm (168 inch. lbs.). 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 6. Lower vehicle to the ground. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1352 Wheel Fastener: Service and Repair Rear REMOVAL CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs cannot be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature hub and bearing failure. The following procedure and special tools shown MUST be used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the rear axle for replacement of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum. Removing Wheel Stud From Hub And Bearing 4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the threads on stud are even with end of lug nut. Install Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud. 5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. Remove lug nut from stud and remove wheel stud from flange. INSTALLATION Installing Wheel Stud Into Hub And Bearing 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 5. Lower vehicle to the ground. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure: Minimum 100 psi with no more than 25% variance between cylinders. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1358 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators: fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System, disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. Refer to Powertrain Management for Specifications. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service Camshaft Bearing: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service NUMBER: 09-007-02 GROUP: Engine DATE: Oct. 21, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Camshaft/Bearing Service MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG) Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES CODES EGA, EGB, EGH, EGM, EGP). DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings must be inspected for wear and/or damage. If wear or damage is present the short block must be replaced. Excessive camshaft bearing wear could result in damage to the new replacement camshaft. Camshaft bearings are only serviced with a short engine assembly. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Page 1364 Camshaft Bearing: Specifications DIAMETER: No. 1 .............................................................................................................................................................. 50.825 - 50.800 mm (2.0009 - 1.9999 inch) No. 2 .............................................................................................................................................................. 50.419 - 50.393 mm (1.9849 - 1.9839 inch) No. 3 .............................................................................................................................................................. 50.038 - 50.013 mm (1.9699 - 1.9690 inch) No. 4 .............................................................................................................................................................. 49.632 - 49.606 mm (1.9540 - 1.9529 inch) Oil Clearance ......................................................................................................................................................... 0.0254 - 0.0762 mm (0.001 - 0.003 inch) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Page 1365 Camshaft Bearing: Service and Repair REMOVAL 1. With engine removed from vehicle and completely disassembled, drive out rear cam bearing core hole plug. Removal/Installation Of Camshaft Bearings With Tool C-3132-A -Typical 2. Install proper size adapters and horseshoe washers (part of Tool C-3132-A) at back of each bearing shell to be removed and drive out bearing shells. INSTALLATION 1. Install new camshaft bearings with Tool C-3132-A by sliding the new camshaft bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. Number two bearing must index with the oil passage to the left cylinder head and Number three bearing must index with the oil passage to the right cylinder head. If the camshaft bearing shell oil holes are not in exact alignment, remove and reinstall them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service Camshaft: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service NUMBER: 09-007-02 GROUP: Engine DATE: Oct. 21, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Camshaft/Bearing Service MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG) Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES CODES EGA, EGB, EGH, EGM, EGP). DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings must be inspected for wear and/or damage. If wear or damage is present the short block must be replaced. Excessive camshaft bearing wear could result in damage to the new replacement camshaft. Camshaft bearings are only serviced with a short engine assembly. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Page 1373 Camshaft: Specifications Camshaft Drive Chain Camshaft Bearings Steel Backed Babbit 4 Diametrical Clearance 0.001 - 0.004 in Max Allowable 0.005 in Thrust Taken By Thrust Plate End Play 0.005 - 0.012 in Max. Allowable 0.012 in Camshaft Journals Bearing Journal Diameter No.1 1.997 - 1.999 in Bearing Journal Diameter No.2 1.9809 - 1.9829 in Bearing Journal Diameter No.3 1.9659 - 1.9679 in Bearing Journal Diameter No.4 1.9499 -1.9520 in Camshaft Bearings Diameter No.1 2.0009 - 1.999 in Diameter No.2 1.9849 - 1.9839 in Diameter No.3 1.9699 - 1.9690 in Diameter No.4 1.954 - 1.9529 in Oil Clearance 0.001 - 0.003 in Valve Timing Exhaust Valve Closes (ATC) 12 deg Opens (BBC) 48 deg Duration 240 deg Valve Timing Intake Valve Closes (BTDC) 58 deg Opens 2 deg Duration 240 deg Valve Overlap 14 deg Camshaft Thrust Plate Bolt 105 in.lb Valves-Intake Lift (Zero Lash) 0.400 in Valves-Exhaust Lift (Zero Lash) 0.40 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Page 1374 Camshaft: Service and Repair REMOVAL 1. Remove engine from vehicle. Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover, and timing chain. 2. Remove hydraulic tappets; identify so each part will be replaced in its original location. Camshaft Thrust Plate 3. Remove camshaft thrust plate. 4. Install a long bolt into front of camshaft to facilitate removal of the camshaft; remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION 1. Lubricate camshaft lobes and camshaft bearing journals. 2. Insert the camshaft to within 2 inches of its final position in cylinder block. 3. Install camshaft thrust plate with two screws. Tighten to 12 Nm (105 inch lbs.) torque. 4. Rotate crankshaft so the timing arrow is at the 12 o'clock position. 5. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock position. 6. Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position. Alignment Of Timing Marks 7. Use a straight edge to check alignment of timing marks. 8. Install the camshaft bolt. Tighten bolt to 54 Nm (40 ft. lbs.). 9. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign. 10. Measure camshaft end play. End Play should measure 0.0127 to 0.304 mm (0.005 to 0.012 inches.) 0.310 mm (0.012 in. Maximum). If not within limits install a new thrust plate. NOTE: When camshaft is replaced, all of the tappets must be replaced. 11. Install hydraulic tappets. Each tappet reused must be installed in the same position from which it was removed. 12. Install timing chain, timing chain cover, cylinder heads, cylinder head covers, and intake manifold. 13. Install engine assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Hydraulic Tappets Roller Hydraulic Body Diameter 0.9035 - 0.9040 in Clearance in Block 0.0007 - 0.0024 in Service Tappets Available 0.001,0.008, 0.030 in Tappet Retainer Yoke Bolt 105 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1378 Lifter / Lash Adjuster: Testing and Inspection Roller Tappets Aligning Yoke And Retainer The valve train includes roller tappet assemblies, aligning yokes and yoke retainer. Roller tappet alignment is maintained by machined flats on tappet body being fitted in pairs into six aligning yokes. The yokes are secured by an alignment yoke retainer. PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS Before disassembling any part of the engine to correct tappet noise, read the oil pressure at the gauge. Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and check the oil level in the oil pan. The pressure should be between 30 and 80 psi (206.8 to 551.6 kPa) at 2000 rpm. The oil level in the pan should never be above the MAX mark on dipstick, or below the MIN mark. Either of these two conditions could be responsible for noisy tappets. Oil Level Check: stop engine after reaching normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. OIL LEVEL TOO HIGH If oil level is above the MAX mark on dip stick, it is possible for the connecting rods to dip into the oil while engine is running and create foam. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to become soft and allow valves to seat noisily. OIL LEVEL TOO LOW Low oil level may allow pump to take in air which when fed to the tappets, causes them to become soft and allows valves to seat noisily. Any leaks on intake side of pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, engine should be operated at fast idle to allow all of the air inside of the tappets to be bled out. VALVE TRAIN NOISE DIAGNOSIS To determine source of valve train noise, operate engine at idle with cylinder head covers removed and listen for source of the noise. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger which will necessitate replacing the tappet, or by the plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet check valve not seating, or by foreign particles becoming wedged between the plunger and the tappet body causing the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation Lifter / Lash Adjuster: Service and Repair Removal and Installation REMOVAL Cylinder head must be removed to gain access to hydraulic tappets for service. 1. Remove cylinder head. 2. Remove yoke retainer and aligning yokes. 3. Use Special Tool C-4129, or equivalent to remove tappets from their bores. If all tappets are to be reused, identify tappets to insure installation in original location. NOTE: If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize and replace with oversize tappet. CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. Do not disassemble a tappet on a dirty work bench. INSTALLATION 1. Lubricate tappets. 2. Install hydraulic tappets. Install tappets in their original positions, if reused. Roller Tappets Aligning Yoke And Retainer 3. Install tappet aligning yokes. 4. Install yoke retainer and torque screws to 12 Nm (105 inch lbs.). 5. Install cylinder heads. 6. Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation > Page 1381 Lifter / Lash Adjuster: Service and Repair Disassembly and Assembly DISASSEMBLY Hydraulic Roller Tappet Assembly 1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above plunger cap. 3. Invert tappet body and remove plunger cap, plunger, flat or ball check valve, check valve spring, check valve retainer and plunger spring. Check valve could be flat or ball. ASSEMBLY 1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear, valve is pitted, or valve seat on end of plunger indicates any condition that would prevent valve from seating, install a new tappet assembly. 4. Assemble tappets. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Shaft Bracket Bolts 250 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1385 Rocker Arm Assembly: Service and Repair ROCKER ARMS AND SHAFT ASSEMBLY REMOVAL 1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and shaft assembly. Rocker Arm Location Left Bank 7. If rocker arm assemblies are disassembled for cleaning or replacement, assemble rocker arms in their original position. INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 inch lbs.). CAUTION: THE ROCKER ARM SHAFT SHOULD BE TORQUED DOWN SLOWLY, STARTING WITH THE CENTER BOLTS. ALLOW 20 MINUTES TAPPET BLEED DOWN TIME AFTER INSTALLATION OF THE ROCKER SHAFTS BEFORE ENGINE OPERATION. 2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten, if necessary. 3. Clean cylinder head sealing surfaces. Install a new gasket and tighten cylinder head cover fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug wires. 6. Install upper intake manifold assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance ........................................................................................................................................... 0.019 0.065 mm (0.00075 - 0.0026 inch) Wear Limit ........................................................................................................................................... ............................................ 0.76 mm (0.003 inch) Side Clearance ....................................................................................................................................................... 0.127 - 0.381 mm (0.005 - 0.015 inch) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts TORQUE SPECIFICATIONS Connecting Rod Cap Nuts .............................................................................................................................................. 54 Nm (40 ft. lbs.) Plus 1/4 turn Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1394 Connecting Rod: Specifications Connecting Rod Specifications Connecting Rod Bearing Type ....................................................................................................................................... ..................................... Aluminum Lead (Bimetal) Bearing Clearance ............................................................................................................................................... 0.019-0.065 mm (0.00075-0.0026 inch) Max. Allowable ..................................................................... ........................................................................................................ 0.076 mm (0.003 inch) Side Clearance ........................................................................................................................................................... 0.127-0.381 mm (0.005-0.015 inch) Connecting Rod Journals Diameter ............................................................................................................................................................ 58.005-57.979 mm (2.2837-2.2827 inch) Out-of-Round (Max.) .......................................................... ........................................................................................................... 0.025 mm (0.001 inch) Taper (Max.) .................................................................................................................................................. ................................ 0.025 mm (0.001 inch) TORQUE SPECIFICATIONS Rod Nut ............................................................................................................................................... ............................ 54 Nm (40 ft. lbs.) plus 1/4 turn Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1395 Connecting Rod: Service and Repair Fit all rods on one bank until complete. The bearing caps are not interchangeable and should be marked at removal to insure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch) and 0.250 mm (0.010 inch) undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps. Checking Connecting Rod Bearing Clearance 1. Follow procedure specified in the Standard Service Information, Measuring With Plastigage, found under Engine, Service and Repair for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance. See: Service and Repair/Standard Procedures/Measuring With Plastigage Check For Stretched (Necked) Bolts NOTE: The rod bearing bolts should be examined before reuse. If the threads are necked down the bolts should be replaced. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced. 2. Before installing the nuts the threads should be oiled with engine oil. 3. Install nuts finger tight on each bolt then alternately torque each nut to assemble the cap properly. 4. Tighten the nuts to 54 Nm PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1396 Checking Connecting Rod Side Clearance 5. Using a feeler gauge, check connecting rod side clearance. Refer to Connecting Rod Specification Chart. Connecting Rod Specification Chart Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Cast Nodular Iron Thrust Location No. 2 Bearing Connecting Rod Journal Diameter 2.124 - 2.125 in Main Bearing Diametrical Clearance No.1-4 0.0043 - 0.0023 in Max. Allowable 0.004 in End Play 0.0036 - 0.0095 in Max. Allowable 0.015 in Main Bearing Journals Diameter 2.5202 - 2.5195 in Out-of-Round 0.001 in Taper (Max.) 0.001 in Connecting Rod Journals Diameter 2.2837 - 2.2827 in Out-of-Round 0.001 in Taper (Max.) 0.001 in Main Bearing Cap Bolts 30 ft.lb plus 1/4 turn Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Cast Nodular Iron Thrust Location No. 2 Bearing Connecting Rod Journal Diameter 2.124 - 2.125 in Main Bearing Diametrical Clearance No.1-4 0.0043 - 0.0023 in Max. Allowable 0.004 in End Play 0.0036 - 0.0095 in Max. Allowable 0.015 in Main Bearing Journals Diameter 2.5202 - 2.5195 in Out-of-Round 0.001 in Taper (Max.) 0.001 in Connecting Rod Journals Diameter 2.2837 - 2.2827 in Out-of-Round 0.001 in Taper (Max.) 0.001 in Main Bearing Cap Bolts 30 ft.lb plus 1/4 turn Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation Crankshaft: Service and Repair Removal and Installation MAIN BEARINGS Main Bearing Cap Identification Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3, and 4 are interchangeable. Upper main bearing halves of 1, 3, and 4 are interchangeable. CRANKSHAFT MAIN JOURNALS Measuring Crankshaft Journal O.D. The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 min (0.012 inch) under the standard journal diameter. Do NOT grind thrust faces of Number 2 main bearing. Do NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1405 Main Bearing Identification Upper and lower number 2 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersizes: 0.025 min (0.001 inch) and 0.254 mm (0.010 inch). Never install an undersize bearing that will reduce clearance below specifications. REMOVAL 1. Remove oil pan and identify bearing caps before removal. Removing And Installing Upper Main Bearing With Special Tool C-3059 2. Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059 into the oil hole of crankshaft. 3. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. INSTALLATION NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1. Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft. 2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059. 3. Install each main cap and tighten bolts finger tight. 4. Tighten number 1, 3 and 4 main cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). 5. Rotate the crankshaft until number 6 piston is at TDC. 6. To ensure correct thrust bearing alignment the following procedure must be done: a. Move crankshaft all the way to the rear of its travel. b. Then, move crankshaft all the way to the front of its travel. c. Wedge a appropriate tool between the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in its most forward position. d. Tighten the #2 Thrust Bearing cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the holding tool. 7. Install oil pan. 8. Fill engine crankcase with proper oil to correct level. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1406 Crankshaft: Service and Repair Service Procedures Crankshaft End Play Measurement DIAL INDICATOR METHOD Checking Crankshaft End Play 1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. Refer to Crankshaft Specification Chart. FEELER GAUGE METHOD 1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage any bearing surface. Do not loosen main bearing cap. 2. Use a feeler gauge between number 2 thrust bearing and machined crankshaft surface to determine end play. Refer to Crankshaft Specification Chart. Crankshaft Specification Chart Fitting Bearings CRANKSHAFT OIL CLEARANCE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1407 Measure Crankshaft Journal O.D. Measure the journal outside diameter. Refer to Crankshaft Specification Chart. Crankshaft Specification Chart CRANKSHAFT SPECIFICATION CHART PLASTIGAGE (OIL CLEARANCE) MEASUREMENT 1. Remove oil from journal and bearing shell. 2. Install crankshaft. Measuring Beaing Clearance With Plastigage Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1408 3. Cut plastigage to same length as width of the bearing and place it in parallel with the journal axis. 4. Install the main bearing cap carefully and tighten the bolts to specified torque. CAUTION: Do not rotate crankshaft or the Plastigage will be smeared. 5. Carefully remove the bearing cap and measure the width of the plastigage at the widest part using the scale on the plastigage package. Refer to Crankshaft Specification Chart for proper clearances. If the clearance exceeds the specified limits, replace the main bearing(s) and if necessary, have the crankshaft machined to next undersize. CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation The engine block heater is available as an optional accessory on all models. The heater is operated by ordinary house current (110 Volt A.C.) through a power cord located behind the radiator grille. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1412 Engine Block Heater: Service and Repair REMOVAL 1. Drain coolant from radiator and cylinder block. 2. Remove power cord plug from heater. 3. Loosen screw in center of heater. Remove heater assembly. INSTALLATION 1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal. 4. Fill cooling system with coolant to the proper level, vent air, and inspect for leaks. Pressurize system with Radiator Pressure Tool before looking for leaks. 5. Install power cord plug to heater. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair REMOVAL Core Hole Plug Removal Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug. CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems. INSTALLATION Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar(R) Stud N' Bearing Mount or equivalent. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into oil gallery hole so that the sharp edge of the plug is at least 0.5 mm (0.020 inch) inside the lead-in chamfer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley Harmonic Balancer - Crankshaft Pulley: Specifications Chrankshaft Pulley Chrankshaft Pulley Torque Specifications 54 Nm (40 ft.lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley > Page 1420 Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Damper Pulley to Crankshaft Bolt 40 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1421 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. 3. Remove right wheel and inner splash shield. 4. Remove drive belt. Crankshaft Damper-Removal 5. Remove crankshaft pulley. INSTALLATION Crankshaft Damper-Installation 1. Install crankshaft pulley using plate L-4524, thrust bearing/washer and C-4685-Cl, 5.9 inch screw. 2. Install drive belt. 3. Install inner splash shield and wheel. 4. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Pistons Aluminum Alloy Tin Coated Clearance at Size Location 0.001 - 0.0022 in Weight (Standard Only)-3.3L 13.4394 +/-0.1764 Weight (Standard Only)-3.8L 15.4501 +/-0.1764 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation Piston: Service and Repair Removal and Installation REMOVAL 1. Disconnect negative cable from battery. 2. Remove cylinder heads and oil pan. 3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. Identify Connecting Rod To Cylinder 4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them, if necessary. Connecting Rod Protectors 5. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. INSTALLING PISTON AND CONNECTING ROD ASSEMBLY Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1427 Piston Ring End Gap Position 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps. 3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor. Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts. Piston-Installation 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. Piston I.D. Notches 7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lbs.) Plus 1/4 turn. 9. Repeat procedure for each piston and rod installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1428 10. Install cylinder heads and oil pan. 11. Fill engine crankcase with proper oil to correct level. 12. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1429 Piston: Service and Repair Fitting Pistons and Rings FITTING PISTONS Piston Measurements Checking Cylinder Bore Size The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. Refer to Cylinder Bore and Piston Specification Chart. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1430 CYLINDER BORE AND PISTON SPECIFICATION CHART Check Gap On Piston Rings FITTING RINGS 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. Refer to Piston Ring Specification Chart. Measuring Piston Ring Side Clearance 2. Check piston ring to groove clearance. Refer to Piston Ring Specification Chart. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1431 Piston Ring Specification Chart Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Pistons Pins Press Fit in Rods (Serrviced as an Assembly) Diameter 0.9009 - 0.9007 in Length-3.3L 2.648 - 2.667 in Length-3.8L 2.805 - 2.824 in Clearance in Piston @70' 0.0002 - 0.0007 in Clearance in Rod (Interference) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Number of Rings 3 Compression 2 Oil Control 1 Oil Ring Type 3-Piece, Steel Rail, Chrome Face Piston Ging Gap Top and 2nd Compression Ring 0.0118 - 0.0217 in Oil Control (Steel Rails) 0.0098 - 0.0394 in Service Rings Ring Gap-Compression 0.0188 - 0.0217 in Ring Gap-Oil Control 0.0098 - 0.0394 in Piston Ring Side Clearance Top and 2nd Compression Rings 0.0012 - 0.0037 in Oil Rings (Steel Rails) 0.0005 - 0.0089 in Piston Ring Width Compression Rings 0.0575 - 0.0591 in Oil Ring (Steel Rails) 0.0201 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1445 Fuel Pressure Release: Service and Repair WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. Fuel Pressure Test Port Releasing Fuel Pressure 3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. 5. Replace Pressure test port cap when finished doing pressure test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Shaft Bracket Bolts 250 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1449 Rocker Arm Assembly: Service and Repair ROCKER ARMS AND SHAFT ASSEMBLY REMOVAL 1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and shaft assembly. Rocker Arm Location Left Bank 7. If rocker arm assemblies are disassembled for cleaning or replacement, assemble rocker arms in their original position. INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 inch lbs.). CAUTION: THE ROCKER ARM SHAFT SHOULD BE TORQUED DOWN SLOWLY, STARTING WITH THE CENTER BOLTS. ALLOW 20 MINUTES TAPPET BLEED DOWN TIME AFTER INSTALLATION OF THE ROCKER SHAFTS BEFORE ENGINE OPERATION. 2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten, if necessary. 3. Clean cylinder head sealing surfaces. Install a new gasket and tighten cylinder head cover fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug wires. 6. Install upper intake manifold assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts 105 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1453 Valve Cover: Service and Repair REMOVAL Cylinder Head Cover-Isolated Type NOTE: The cylinder head cover can be either an isolated type or a non-isolated type. FRONT CYLINDER HEAD COVER 1. Disconnect ignition cables from spark plugs. 2. Disconnect crankcase vent hose from cylinder head cover. 3. Remove front cylinder head cover bolts. 4. Remove cylinder head cover and gasket. REAR CYLINDER HEAD COVER 1. Disconnect negative cable from battery. 2. Remove wiper unit. 3. Remove intake manifold upper plenum. 4. Disconnect PCV hose from cylinder head cover. 5. Remove rear cylinder head cover bolts 6. Remove cylinder head cover and gasket. INSTALLATION FRONT CYLINDER HEAD COVER 1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. 2. Install cylinder head cover and bolts. 3. Tighten cylinder head cover bolts to the following specifications: - Non-isolated cylinder head cover to 12 Nm (105 inch lbs.). - Isolated cylinder head cover to 10 Nm (90 inch lbs.). 4. Connect crankcase vent hose. 5. Connect ignition cables to spark plugs. REAR CYLINDER HEAD COVER 1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. 2. Install cylinder head cover and bolts. 3. Tighten cylinder head cover bolts to the following specifications: ^ Non-isolated cylinder head cover to 12 Nm (105 inch lbs.). ^ Isolated cylinder head cover to 10 Nm (90 inch lbs.). 4. Connect PCV hose from cylinder head cover. 5. Install intake manifold upper plenum. 6. Install wiper unit. 7. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Dimensions Valve Guide: Specifications Overall Length-Intake 1.732 in Overall Length-Exhaust 1.889 in Outside Diameter 0.514 - 0.5143 in Inside Diameter 0.314 - 0.315 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Dimensions > Page 1458 Valve Guide: Specifications Type Guide Type Specifications Guide Material ..................................................................................................................................... ......................................... Powdered Metal Inserts Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1459 Valve Guide: Service and Repair NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize reamer, or if guide is loose in cylinder head. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle-Intake and Exhaust 45 - 45.5 deg Runout (Max.) 0.003 in Width (Finish)-Intake 0.069 - 0.088 in Width (Finish)-Exhaust 0.057 - 0.078 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1463 Valve Seat: Service and Repair Refer to Valve, Intake/Exhaust, Service and Repair, Valve Service/Recondition for procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length (Approx.) 1.909 in Wire Diameter 0.187 in Number of Coils 6.8 Spring Tension (Valve Closed) 95 - 100 lbf at 1.57 in Spring Tension (Valve Open) 207 - 229 lbf at 1.169 in Installed Height (Spring Seat to Bottom of Retainer) 1.622 - 1.681 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off Valve Spring: Service and Repair Cylinder Head Off Refer to Valve, Intake/Exhaust, Service and Repair for procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1469 Valve Spring: Service and Repair Cylinder Head On 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative cable from battery 3. Remove air cleaner cover and hose assembly. 4. Remove upper intake manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove electrical connector from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the number 1 piston is at TDC on the compression stroke. 8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to hold valves in place while servicing components. 10. Using Tool C-4682 or equivalent, compress valve spring and remove retainer valve locks and valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do not force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide. 12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being covered. 13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14 Nm (120 inch lbs.) and electrical connector to ignition coils. 16. Install intake manifold. 17. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1470 Valve Spring: Service and Repair Inspection Refer to Valve, Intake/Exhaust, Service and Repair for procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valves-Intake Face Angle 44.5 deg Head Diameter 1.79 in Lenght (Overall) 5.000 - 5.041 in Minimum Valve Length After Tip Grinding 4.916 in Stem Diameter (Standard) 0.312 - 0.313 in Valve Tip Height (From Cylinder Head Surface) 1.950 - 2.018 in Stem-to-Guide Clearance 0.001 - 0.003 in Max. Allowable (Rocking Method) 0.010 in Valves for Service (Oversize Stem Diameters) 0.005, 0.015, 0.030 in Valves-Exhaust Face Angle 45 deg Head Diameter 1.476 in Legth Overall 5.032 - 5.058 in Minimum Valve Length After Grinding 4.941 in Valve Tip Height (From Cylinder Head Surface) 1.950 - 2.018 in Stem Diameter (Strandard) 0.3112 - 0.3119 in Stem to Guide Clearance 0.002 - 0.006 in Max. Allowable (Rocking Method) 0.016 in Valves for Service (Oversize Stem Diameters 0.005, 0.015, 0.030 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL Compress Valve Springs With Special Tool C-3422-B With Adapter 6412 1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-B with adapter 6412. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. VALVE INSTALLATION 1. Coat valve stems with clean engine oil and insert them in cylinder head. Checking Valve Installed Height 2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to give 49.541 to 51.271 mm (1.950 to 2.018 inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip chamfer should be reground to prevent seal damage when the valve is installed. Valve Seal And Spring-Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1476 3. Install valve spring seat spacer on head. 4. Install new cup seals on all valve stems and over valve guides. Install valve springs and valve retainers. 5. Compress valve springs with Valve Spring Compressor Tool C-3422-13, with adapter 6412 install locks and release tool. If valves and/or seats are reground, measure the installed height of springs dimension B, make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore to bring spring height back to normal 1-17/32 to 1-19/32 inch (39.1 to 40.6 mm). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1477 Valve: Service and Repair Valve Service Intake And Exhaust Valves VALVE INSPECTION 1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve stems for wear. Refer to Valve Specification. CAUTION: Valve stems are chrome plated and should not be polished. 3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4. Measure valve stem guide clearance as follows: a. Install valve into cylinder head so it is 14 mm (0.551 inch) off the valve seat. A small piece of hose may be used to hold valve in place. Measuring Valve Guide Wear b. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured. 5. Move valve to and from the indicator. Refer to Valve Guide Specification Chart. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1478 VALVE GUIDE SPECIFICATION CHART 6. Ream the guides for valves with oversized stems if dial indicator reading is excessive or if the stems are scuffed or scored. 7. Service valves with oversize stems and over size seals are available in 0.15 mm (0.005 inch), 0.40 mm, (0.015 inch) and 0.80 mm (0.030 inch) oversize. NOTE: Oversize seals must be used with oversize valves. 8. Refer to Valve Guide Specification Chart for reamer size to accommodate the oversize valve stems. 9. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Do not attempt to ream the valve guides from standard directly to 0.80 mm (0.030 inch). Use step procedure of 0.15 mm (0.005 inch), 0.40 mm (0.015 inch) and 0.80 mm (0.030 inch) so the valve guides may be reamed true in relation to the valve seat. After reaming guides, the seat runout should be measured and resurfaced if necessary. See Refacing Valves and Valve Seats. VALVE GUIDES NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize reamer, or if guide is loose in cylinder head. REFACING VALVES AND VALVE SEATS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1479 Valve Seats The intake and exhaust valves have a 44-1/2 to 45 degree face angle. The valve seats have a 45 to 45-1/2 degree face angle. The valve face and valve seat angles are shown in the image.. VALVES 1. Inspect the remaining margin after the valves are refaced. Refer to Valve Specification Chart. VALVE SPECIFICATION CHART VALVE SEATS Refacing Valve Seats CAUTION: Remove metal from valve seat only. Do not remove metal from cylinder head. 1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1480 3. Inspect the valve seat using Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degree stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced. Valve Seats 4. When seat is properly positioned, the width of intake seats should be 1.75 to 2.25 mm (0.69 to 0.088 inch). The width of the exhaust seats should be 1.50 to 2.00 mm (0.059 to 0.078 inch). Checking Valve Installed Height (Part 1 Of 2) Checking Valve Installed Height (Part 2 Of 2) 5. Check the valve spring installed height after refacing the valve and seat. TESTING VALVE SPRINGS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1481 Testing Valve Springs Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example, the compression length of the spring to be tested is 33.34 mm (1-5/16 inches). Turn table of Tool C-647 until surface is in line with the 33.34 mm (1-5/16 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1491 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1496 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1497 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1498 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1504 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1509 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1510 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1511 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1512 Accessory Drive Belt-3.3/3.8L Engines Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1513 Drive Belt: Description and Operation The accessory drive system utilizes two different style of drive belts. The conventional V-belt and the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump and water pump. Satisfactory performance of these belts depends on belt condition and proper belt tension. Belt tensioning should be performed with the aid of a Belt Tension Gauge, Special Tool 7198. Because of space limitations in the engine compartment, the use of this gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the drive belts, if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1514 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1515 Drive Belt: Adjustments Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning should be performed with the aid of Special Tool 7198. Because of space limitations in the engine compartment, the use of this gauge may be restricted. Raise the vehicle on a hoist and the remove the splash shield to gain access to the drive belts, if necessary. BELT TENSION GAUGE METHOD Use belt tension gauge, Special Tool 7198. Adjust belt tension for either a New or Used belt. For specifications, refer to Belt Tension Chart. BELT TENSION CHART Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation A/C Belt Refer to Drive Belt, Alternator for procedure. Alternator Belt Accessory Drive Belt-3.3/3.8L Engines The Poly-V serpentine drive belt is provided with a dynamic tensioner to maintain proper belt tension to drive the following components: ^ generator ^ power steering pump ^ air conditioning compressor ^ water pump REMOVAL 1. Raise vehicle on hoist. Accessory Drive Belt Splash Shield 2. Remove accessory drive belt splash shield. WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO TENSIONER AND/OR PERSONAL INJURY COULD RESULT. 3. Release belt tension by rotating the tensioner clockwise. 4. Remove drive belt. INSTALLATION 1. Properly route and position belt onto all pulleys, except for the tensioner pulley. 2. Rotate belt tensioner clockwise until belt can be installed onto the tensioner pulley. Slowly release belt tensioner. 3. Verify belt is properly routed and engaged on all pulleys. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1518 4. Install splash shield and lower vehicle. Power Steering Belt Refer to Drive Belt, Alternator for procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1519 Drive Belt: Service and Repair Cleaning and Inspection Serpentine Drive Belt Wear Patterns When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks running along the rib (not across) are not normal. Any belt with cracks running along the rib must be replaced. Also replace the belt if it has excessive wear, frayed cords, or severe glazing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Page 1520 Belt Tension Gauge 7198 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Accessory Drive Belt Tensioner Assembly Fastener 45 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Adjustments Engine Mount: Adjustments 1. Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. 2. Loosen the right engine mount insulator vertical fastener and the fore and aft fasteners, and the front engine mount bracket to front crossmember screws. 3. Pry the engine right or left as required to achieve the proper drive shaft assembly length. Refer to Transmission and Drivetrain for driveshaft identification and related assembly length measuring. 4. Tighten engine mounts and fasteners in the following order: a. Right engine mount insulator vertical bolts to 102 Nm (75 ft. lbs.) and the fore and aft bolts to 150 Nm (110 ft. lbs.). b. Front engine mount screws to 54 Nm (40 ft. lbs.) the clearance between the snubbers and the engine should be 2 mm (0.078 inch) each side. c. Left engine mount through bolt to 75 Nm (55 ft. lbs.). 5. Recheck driveshaft length. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount FRONT MOUNT REMOVAL 1. Support the engine and transmission assembly with a floor jack so it will not rotate. Engine Mount-Front 2. Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket. 3. Remove six screws from air dam to allow access to the front mount screws. 4. Remove the front engine mount screws and remove the insulator assembly. 5. Remove the front mounting bracket, if necessary. INSTALLATION 1. Reverse removal procedure for installation and tighten fasteners (Fig. 24) to the following torque. - (A), (C) and (D) to 68 Nm (50 ft. lbs.) - (B) to 102 Nm (75 ft. lbs.) - (E) to 54 Nm (40 ft. lbs.) 2. Install six screws to air dam and tighten to 12 Nm (105 inch lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1529 Engine Mount: Service and Repair Left Mount LEFT SIDE MOUNT REMOVAL 1. Raise vehicle on hoist and remove left front wheel. 2. Support the transmission with a transmission jack. 3. Remove the insulator through bolt from the mount. 4. Remove the transmission mount fasteners and remove mount. INSTALLATION 1. Reverse removal procedure for installation. 2. Tighten mount to transmission bolts to 55 Nm (40 ft. lbs.). Engine Mounting-Left 3. Tighten through bolt to 75 Nm (55 ft. lbs.). 4. Adjust engine mount, refer to Adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1530 Engine Mount: Service and Repair Rear Mount REAR MOUNT REMOVAL 1. Raise vehicle on hoist. 2. Support the transmission with a transmission jack so it will not rotate. 3. Remove the insulator through bolt from the mount and rear suspension crossmember. 4. Remove the four transmission mount fasteners and remove the mount. INSTALLATION Engine Mounting-Rear 1. Reverse the removal procedure for installation. Tighten through bolt to 75 Nm (55 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1531 Engine Mount: Service and Repair Right Mount RIGHT SIDE MOUNT REMOVAL NOTE: Right mount should only be serviced as an assembly to prevent noise, vibration and harshness concerns. 1. Remove the purge duty solenoid and wiring harness from engine mount. Engine Mount-Right 2. Remove the two right engine mount insulator vertical fasteners and loosen the horizontal fastener, do not remove the large nut on the end of the core from frame rail. 3. Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. 4. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. INSTALLATION 1. Reverse removal procedure for installation. Tighten assembly in the following order: a. Engine mount to rail fasteners to 68 Nm (50 ft. lbs.). b. The vertical engine fastener to 102 Nm (75 ft. lbs.). c. The horizontal fastener to 150 Nm (111 ft. lbs.). 2. Install the purge duty solenoid and wiring harness to the engine mount. 3. Adjust engine mount, refer to Adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1532 Engine Mount: Service and Repair Rubber Insulators ENGINE MOUNT RUBBER INSULATORS Insulator location on (right side) is adjustable to allow right/left drive train adjustment in relation to drive shaft assembly length. Check and reposition right engine mount insulator. See Adjustments. Adjust drive train position, if required, for the following conditions: a. Drive shaft distress. b. Any front end structural damage (after repair). c. Insulator replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Idler Pulley: Customer Interest Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1541 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1542 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1543 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Idler Pulley: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1549 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1550 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1551 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1557 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1563 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum Pressure at Idle (Engine Fully Warmed Up)* ............................................................................................................................. 34.47 kPa (5 psi) At 3000 rpm ............................................................................................................................................. ....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting ........................................................................................................................................................... 62-103 kPa (9-15 psi) Oil Filter Type ................................................................................................... ..................................................................................................... Full Flow Oil Pressure Switch Actuating Pressure (Min) ........................................................................................................................................ 14-28 kPa (2-4 psi) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1568 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE Checking Oil Pump Pressure Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5 psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000 RPM. 1. Remove pressure sending unit and install oil pressure gauge. CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM. 2. Warm engine at high idle until thermostat opens. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Drain Plug 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 3.8L (4.0 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1576 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1577 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Bypass Valve Setting 9 - 15 psi Oil Filter Type Full Flow Oil Pressure Switch Actuating Pressure (Min.) 2 - 4 psi Oil Filter Attaching Nipple 30 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1581 Oil Filter: Service and Repair Oil Filter CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using suitable oil filter wrench, turn filter counterclockwise to remove from base. Properly discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft. lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Testing and Inspection Oil Level Warning Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Bolts 105 in.lb Drain Plug 20 in.lb Level Sensor Plug 30 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation Oil Pan: Service and Repair Removal and Installation REMOVAL 1. Disconnect negative cable from battery and remove engine oil dipstick. 2. Raise vehicle on hoist and drain engine oil. 3. Remove bending brace to transaxle attaching bolt. 4. Remove bolts attaching dust cover to transaxle housing. Lower dust cover to gain access to oil pan bolts. 5. Remove oil pan screws and remove oil pan. INSTALLATION Oil Pan Sealing 1. Clean surfaces and apply a 1/8 inch bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent, at the parting line of the chain case cover and the rear seal retainer. Oil Pan Gasket Installation 2. Use a new pan gasket. 3. Install pan and tighten screws to 12 Nm (105 in. lbs.). 4. Install dust shield and bending brace to transaxle housing. 5. Lower vehicle and install oil dipstick. 6. Connect negative cable to battery. 7. Fill crankcase with oil to proper level. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation > Page 1590 Oil Pan: Service and Repair Cleaning and Inspection 1. Clean oil pan in solvent and wipe dry with a clean cloth. Clean all gasket material from mounting surfaces of pan and block. 2. Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary. Install a new drain plug gasket. Tighten to 27 Nm (20 ft. lbs.). 3. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. 4. Clean oil screen and pipe in clean solvent. Inspect condition of screen. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Gauge Sending Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1597 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1598 Oil Pressure Sender: Diagrams Engine Oil Pressure Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum Pressure at Idle (Engine Fully Warmed Up)* ............................................................................................................................. 34.47 kPa (5 psi) At 3000 rpm ............................................................................................................................................. ....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting ........................................................................................................................................................... 62-103 kPa (9-15 psi) Oil Filter Type ................................................................................................... ..................................................................................................... Full Flow Oil Pressure Switch Actuating Pressure (Min) ........................................................................................................................................ 14-28 kPa (2-4 psi) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1606 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE Checking Oil Pump Pressure Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5 psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000 RPM. 1. Remove pressure sending unit and install oil pressure gauge. CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM. 2. Warm engine at high idle until thermostat opens. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications INTAKE MANIFOLD: Lower Intake Mounting Bolts ......................................................................................................................................................... 23 Nm (200 inch lbs.) Upper Plenum Bolts .............................................................................................. .......................................................................... 28 Nm (250 inch lbs.) Plenum Support Bracket ....... .............................................................................................................................................................. .. 54 Nm (40 ft. lbs.) TORQUE SEQUENCE: Intake Manifold Bolts Location And Tightening Sequence Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection INSPECTION Check for: ^ Damage and cracks of each section. ^ Clogged water passages in end cross-overs (if equipped). ^ Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. CLEANING Remove the gasket material from the manifold surfaces. Be careful not to gouge or scratch the sealing surface. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1612 Intake Manifold: Service and Repair Intake Manifold Replacement Removal 1. Remove windshield wiper module. 2. Perform fuel system pressure release procedure (before attempting any repairs). 3. Drain cooling system. 4. Remove air inlet resonator to throttle body hose assembly. 5. Remove throttle cable. Remove wiring harness from throttle cable bracket. 6. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body. 7. Remove EGR transducer connector. 8. Remove vacuum hose harness from throttle body. 9. Remove PCV and brake booster hoses from air intake plenum. 10. Disconnect MAP Sensor electrical connection. 11. Remove EGR tube flange from intake plenum. 12. Remove vacuum harness connectors from intake plenum. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1613 13. Remove cylinder head to intake plenum strut. 14. Remove the engine mounted ground strap. 15. Remove the fuel hose quick connect fitting from the fuel line by using an open end wrench pushing in on the plastic ring located on the end of the fittings. Gently pull the fitting from the fuel line. CAUTION: Wrap a shop towel around hoses to catch any gasoline spillage during removal. 16. Remove Direct Ignition System (DIS) coils and generator bracket to intake manifold bolt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1614 17. Remove bolts from generator to intake manifold bracket. Loosen top generator mounting bolt, and move bracket up so intake manifold can clear mounting studs. 18. Remove intake manifold bolts and remove the manifold. 19. Cover intake manifold with suitable cover when servicing. 20. Remove vacuum harness connector from Fuel Pressure Regulator. 21. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer bracket to allow fuel tube removal clearance. 22. Disconnect cam sensor and coolant temperature sensor. 23. Remove fuel injector wiring clip from intake manifold water tube. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1615 24. Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their ports. Intake Manifold Bolts Location And Tightening Sequence 25. Remove upper radiator hose, bypass hose and rear intake manifold hose. 26. Remove intake manifold bolts. Remove intake manifold. 27. Inspect and clean manifold. WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1616 28. Remove intake manifold seal retainers screws. Remove intake manifold gasket. Installation 1. Clean all surfaces of cylinder block and cylinder heads. 2. Place a drop (approximately 1/4 inch diameter) of Mopar (R) Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners. 3. Carefully install the new intake manifold gasket. Torque end seal retainer screws to 12 Nm (105 inch lbs.). Intake Manifold Bolts Location And Tightening Sequence 4. Install intake manifold and bolts and torque to 1 Nm (10 inch lbs.). Then torque bolts to 22 Nm (200 inch lbs.) in sequence shown. Then torque again to 22 Nm (200 inch lbs.). After intake manifold is in place, inspect to make sure seals are in place. 5. Make sure the injector holes are clean and all plugs have been removed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1617 6. Lube injector O-ring with a drop of clean engine oil to ease installation. 7. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports. 8. Install the fuel rail attaching bolts and torque to 22 Nm (200 inch lbs.). 9. Install fuel tube retaining bracket screw and torque to 4 Nm (35 inch lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1618 10. Connect cam sensor and coolant temperature sensor. 11. Connect fuel pressure regulator vacuum line. 12. Remove covering on lower intake manifold and clean surface. 13. Place the new intake manifold gasket on lower manifold. Put upper manifold into place and install bolts and nuts finger tight. NOTE: At no time should the studs be replaced with a bolt and washer. 14. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. (Do not torque.) 15. Torque intake manifold bolts to 28 Nm (250 inch lbs.) following torque sequence. 16. Torque generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1619 17. Torque the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.). 18. Connect ground strap and MAP sensor electrical connectors. 19. Connect vacuum harness to intake plenum. 20. Using a new gasket, connect the EGR tube flange to the intake manifold and torque to 22 Nm (200 inch lbs.). 21. Clip wiring harness into the hole in the throttle cable bracket. 22. Connect the wiring connectors to the Throttle Position Sensor (TPS) and Automatic Idle Speed (AIS) motor. 23. Connect vacuum harness to throttle body. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1620 24. Install the Direct Ignition System (DIS) coils. Torque fasteners to 12 Nm (105 inch lbs.). 25. Lubricate the end of the chassis fuel tube with 30 WT oil. Connect fuel supply hose to chassis fuel tube assembly. Pull back on the quick connect fitting to ensure complete insertion. 26. Install throttle cable. 27. Connect fuel injector wiring harness. 28. Install air cleaner and hose assembly. 29. Connect negative battery cable. 30. With the Diagnostic Readout Box (DRB) Scan Tool use Auto Shutdown (ASD) Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, The ASD Relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Testing and Inspection Oil Level Warning Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL Rear Crankshaft Oil Seal-Removal 1. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal. Angle the pry tool through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry tool blade against crankshaft edge (chamfer) is permitted. INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. Rear Crankshaft Oil Seal-Installation 1. Place Special Tool 6926-1 magnetic pilot tool on crankshaft. 2. Lightly coat seal O.D. with Mopar(R) Stud N' Bearing Mount Adhesive or equivalent. 3. Place seal over Special Tool 6926-1 Pilot. Using Special Tool 6926-2 Installer with C-4171 Handle, drive seal into the retainer housing. REAR CRANKSHAFT SEAL RETAINER When retainer removal is required, remove retainer and clean engine block and retainer of old gasket. Make sure surfaces are clean and free of oil. Install new gasket and tighten screws to 12 Nm (105 inch lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. Remove right wheel and inner splash shield. 3. Remove accessory drive belt. Crankshaft Damper-Removal 4. Remove crankshaft damper. Front Crankshaft Oil Seal-Removal 5. Remove oil seal using Special Tool 6341. Be careful not to damage the crankshaft seal surface of cover. INSTALLATION Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1638 Crankshaft Oil Seal-installation 1. Install new seal using Special Tool C-4992. 2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. Crankshaft Damper-Installation 3. Install crankshaft pulley using plate L-4524. Thrust Bearing/washer and C-4685-C1, 5.9 inch screw. 4. Install accessory drive belt. 5. Install inner splash shield and wheel. 6. Lower vehicle and connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Refer to Valve Spring, Service and Repair, Replacement With Engine Installed for procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Gauge Sending Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1646 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1647 Oil Pressure Sender: Diagrams Engine Oil Pressure Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Number of Links 64 Pitch 0.375 in Width 0.750 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch Timing Chain: Service and Repair Measuring Timing Chain Stretch 1. Place a scale next to timing chain so that any movement of chain may be measured. 2. Place a torque wrench and socket on camshaft sprocket attaching bolt and apply torque in direction of crankshaft rotation to take up slack: 41 Nm (30 ft. lbs.) with cylinder head installed or 20 Nm (15 ft. lbs.) with cylinder heads removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block crankshaft to prevent rotation. Measuring Timing Chain Wear And Stretch 3. Holding a scale even, with dimension reading as shown, along edge of chain links. Apply torque in the reverse direction to 41 Nm (30 ft. lbs.) with cylinder heads installed, or 20 Nm (15 ft. lbs.) with cylinder heads removed. Check amount of chain movement. 4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). 5. If chain is not satisfactory, refer to Timing Chain Removal and Installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 1657 Timing Chain: Service and Repair Timing Chain Replacement REMOVAL 1. Disconnect negative cable from battery. 2. Remove timing cover. 3. Remove camshaft sprocket attaching bolt, and timing chain with camshaft sprocket. 4. Using a suitable puller remove the crankshaft sprocket. Be careful not to damage the crankshaft surface. INSTALLATION 1. Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be sure sprocket is seated into position. 2. Rotate crankshaft so the timing arrow is to the 12 o'clock position. 3. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock position. 4. Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position. Timing Marks Alignment 5. Use a straight edge to check alignment of timing marks. 6. Install camshaft bolt and washer. Tighten to 54 Nm (40 ft. lbs.). 7. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign. 8. Check camshaft end play. With new thrust plate the specification is 0.0127 to 0.304 min (0.005 to 0.012 inch). Old thrust plate specification is 0.31 mm (0.012 inch) maximum. If not within these limits, install new thrust plate. 9. Install timing chain cover and connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Cas Cover Bolt-M8 x 1.25 20 ft.lb Timing Chain Case Cover Bolt-M10 x 1.5 40 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1661 Timing Cover: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Drain cooling system. 3. Support engine and remove right engine mount. 4. Raise vehicle on hoist. Drain engine oil. 5. Remove oil pan and oil pump pick-up. It may necessary to remove transaxle inspection cover. 6. Remove right wheel and inner splash shield. 7. Remove accessory drive belt. 8. Remove A/C compressor and set aside. 9. Remove A/C compressor mounting bracket. Crankshaft Damper-Removal 10. Remove crankshaft damper. 11. Remove idler pulley from engine bracket. Engine Bracket 12. Remove engine bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1662 Timing Chain Case Cover 13. Remove cam sensor from timing chain cover. 14. Remove timing chain cover. INSTALLATION 1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement. NOTE: DO NOT USE SEALER ON COVER GASKET Timing Chain Case Cover Gaskets And O-Rings 2. Use a new cover gasket, and O-rings. Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is flush to 0.5 mm (0.020 inch) past the lower edge of the cover. 3. Rotate crankshaft so that the oil pump drive flats are in the vertical position. 4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats. CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result. 5. Install cover onto crankshaft. 6. Install timing chain cover screws and torque to 27 Nm (20 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1663 Crankshaft Oil Seal-Installation 7. Install crankshaft oil seal. Crankshaft Damper-Installation 8. Install crankshaft damper. 9. Install engine bracket and torque fasteners to 54 Nm (40 ft. lbs.). 10. Install idler pulley on engine bracket. 11. Install cam sensor. 12. Install A/C compressor mounting bracket. 13. Install A/C compressor. 14. Install accessory drive belt. 15. Install inner splash shield and wheel. 16. Install oil pump pick-up, oil pan, and transaxle inspection cover, if removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling system. 20. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Key On, Engine Off .............................................................................................................................. ......................................... (approx.) 338 kPa (49 psi) Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1669 Fuel Pressure: Capacity Specifications Information not supplied by the manufacturer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1673 Idle Speed: Testing and Inspection 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. PCV Valve 4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6. Air Metering Fitting 6457 a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b. Disconnect the idle purge line from the throttle body nipple. 7. a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector. 8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 10. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum air-flow is set correctly. IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above 1000 Miles = 575-875 RPM 12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1674 b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle purge line. 16. Remove DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Air Inlet Resonator 1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves together. Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1679 Air Cleaner Element 4. Remove element from air cleaner housing. INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1684 Fuel Pressure Release: Service and Repair WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. Fuel Pressure Test Port Releasing Fuel Pressure 3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. 5. Replace Pressure test port cap when finished doing pressure test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable = Maximum Resistance #1 = 18.5 K Ohms #2 = 15.5 K Ohms #3 = 20.4 K Ohms #4 = 21.2 K Ohms #5 = 27.7 K Ohms #6 = 26.7 K Ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1695 Ignition Cable: Description and Operation DESCRIPTION The spark plug cables and spark plug boots are made from high temperature silicon materials. The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. They also identify proper heat shield installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The bottom of the spark plug heat shield must make contact with the spark plug hex. The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1696 Ignition Cable: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. Spark Plug Cables # 3 And # 5 REMOVAL 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 3. Remove the cable from the retaining bracket. Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. Spark Plug Cable # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove the cable from the retaining bracket. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1700 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1701 Spark Plug: Description and Operation SPARK PLUGS RESISTER DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Setting Spark Plug Electrode Gap Refer to the Specifications for gap and type of spark plug. SPARK PLUGS PLATINUM DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule. All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads The spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions per schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both electrode ends as shown. Extreme care must be used to prevent spark plug cross threading, mis-gaping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1702 Spark Plug: Testing and Inspection Spark Plug Condition Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Normal Operating Conditions Normal Operation And Cold (Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and then reinstalled. CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones. Oil Or Ash Encrusted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1703 Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Electrode Gap Bridging Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Scavenger Deposits Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1704 Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. Spark plugs with chipped electrode insulators must be replaced. Preignition Damage Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1705 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1706 Spark Plug: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation Use extreme care when removing and installing the spark plug cables. The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly Spark Plug # 3 AND # 5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator]ator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. Spark Plug # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure: Minimum 100 psi with no more than 25% variance between cylinders. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1710 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators: fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System, disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. Refer to Powertrain Management for Specifications. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1717 Water Pump: Description and Operation The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain case cover, using an O-ring for sealing. It is driven by the back surface of the Poly-V Drive Belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1718 Water Pump: Testing and Inspection Replace the water pump if it has any of the following defects: 1. Damage or cracks on the pump body. 2. Coolant leaks: If the seal is leaking, this will be evident by traces of thick deposits of greenish-brown dried glycol running down the pump body and components below. A thin black stain below pump weep hole is considered normal operation. 3. Impeller rubs inside of chain case cover or cylinder block. 4. Excessively loose or rough turning bearing. NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1719 Water Pump: Service and Repair REMOVAL 1. Drain Cooling System. 2. Remove accessory drive belt. 3. Remove right front lower fender shield. 4. Remove water pump pulley bolts and remove pulley. Water Pump-3.3/3,8L Engines 5. Remove water pump mounting screws. Remove water pump. 6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface. INSTALLATION Water Pump Body 1. Install new O-ring into groove. 2. Install water pump to chain case cover. Tighten screws to 12 Nm (105 inch lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump. Install screws and tighten to 30 Nm (250 inch lbs.). 5. Install accessory drive belt. 6. Install right front lower fender shield. 7. Refill Cooling System. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY 2.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 10.6 L (11.23 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .................................................................. N/A Rear Heater ............................................................... ............................................................................................................................................. N/A 3.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ........................................................................................................................ 15.0 L (15.9 qts) 3.3/3.8L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) Trailer Tow Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) NOTE: Capacities include heater and coolant recovery tank filled to Max level. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1725 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1726 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description and Operation Coolant: Description and Operation The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the radiator, where the tube/fin assemblies of these components can give it up to the air. The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar(R) Antifreeze or the equivalent is recommended for best engine cooling without corrosion, when mixed only to a freeze point of -37°C (-35°F) to -5C (-50F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description and Operation > Page 1729 Coolant: Description and Operation Coolant Performance Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for each degree of temperature rise for each pound of water). This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: ^ Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). ^ 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point to -22°C (-8°F). ^ 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, sending unit and heater are all designed for 50/50 glycol. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -59°C (-50°F). CAUTION: Richer mixtures cannot be measured with field equipment. This can lead to problems associated with 100 percent glycol. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1730 Coolant: Testing and Inspection Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, Rush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -59°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. Hydrometers test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 70% by volume glycol). Refractometers test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is only recommended for limited usage. Refer to appropriate Technical Service Bulletin(s) regarding use of propylene glycol based coolants. CAUTION: Do not mix types of coolant. Corrosion protection will be severely reduced. Because ethylene glycol and propylene glycol do not have the same specific gravities, the use of a hydrometer will be inaccurate. Therefore, Special Tool 8286 refractometer, must be used when testing coolant. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1731 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams Radiator Cooling Fan Motor: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1736 Radiator Cooling Fan Motor: Description and Operation Cooling fans are pulse width modulated variable speed fans controlled by the PCM through a solid state relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1737 Radiator Cooling Fan Motor: Testing and Inspection Fan control is accomplished two ways. A pressure transducer on the compressor discharge line sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the PCM. The fan will not run during cranking until the engine starts no matter what the coolant temperature is. CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support. The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is properly attached to prevent the following: - Intermittent engine overheating. - Relay "thermal" shutdown, or relay damage. For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and Inspection /Diagnostic Charts/Trouble Code Tests (TC)/TC-14A Rad Fan Control Relay Circuit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1738 Radiator Cooling Fan Motor: Service and Repair Fan Module FAN MODULE REMOVAL There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as an assembly. 1. Raise the vehicle on hoist. 2. Remove the radiator outlet hose from hose retaining clip and remove clip from shroud. 3. Lower the vehicle. Remove the air intake resonator from the throttle body and air cleaner assembly. 4. Disconnect the cooling fan electrical connector. Connector is located on the left side of the fan module. 5. Remove the Coolant Recovery/Reserve System (CRS) attaching screw from the upper crossmember. 6. Remove upper grill to crossmember valence panel. 7. Disconnect the upper radiator mounts from the crossmember. Remove the upper crossmember. 8. Remove the air cleaner assembly. 9. Remove fan module retaining fasteners. 10. Disconnect and plug the transmission line from the radiator fitting on the left side. 11. Raise vehicle on the hoist and remove the filter/drier, fan module and radiator mounting bolts located on the lower right of the fan module. 12. Lower the vehicle on hoist and remove the upper fan module to radiator retaining clips. 13. Remove the fan module from the vehicle. INSTALLATION 1. Install fan module assembly into attaching clips on the radiator. 2. Install the upper fan module to radiator retaining clips. 3. Raise vehicle on the hoist and install the filter/drier, fan module and radiator mounting fasteners located on the lower right of the module. 4. Lower the vehicle. Connect the transmission line to the radiator fitting on the lower left side. 5. Install fan module retaining fasteners. Tighten to 12 Nm (105 inch lbs.). 6. Install the air cleaner assembly. 7. Install the crossmember. Tighten fasteners to 12 Nm (105 inch lbs.). 9. Install the Coolant Recovery/Reserve System (CRS) attaching screw to the upper crossmember. Tighten to 2 Nm (18 inch lbs.). 10. Install upper grill to crossmember valence panel. 11. Connect the cooling fan module electrical connector. Connector is located on the left side of the fan module. 12. Install the air intake resonator to the throttle body and air cleaner assembly. 13. Raise the vehicle. 14. Install outlet hose retainer clip to the shroud. Install the radiator outlet hose to the retaining clip. 15. Lower the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions Radiator Cooling Fan Motor Relay: Technical Service Bulletins Cooling System - Cooling Fan Relay Revisions NUMBER: 26-10-99B GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the cooling fan relay information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1743 7-1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1744 7-12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1745 7-25 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1746 7-25A Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1747 7-25B Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1748 14-49 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1749 Radiator Cooling Fan Motor Relay: Locations Engine Compartment Connections - Early Build Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1750 Engine Compartment Connections - Late Build Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1751 Fan Control Module The SSFR (Solid State Fan Relay) is located on the left front inner frame just behind the radiator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Radiator Cooling Fan Motor Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 A/C & Heater -- Sheet 8w-42-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 1773 Radiator Cooling Fan Motor Relay: Description and Operation SOLID STATE FAN RELAY-PCM OUTPUT The radiator fan runs at a variable speed depending on coolant temperature and A/C system pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR). A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR. Depending upon the amount of pulse on time, the SSFR puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 102 °C (215 °F) the PCM grounds the SSFR relay. If engine coolant reaches 207 °C (225 °F) the PCM grounds the high speed ground relay and high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and high speed ground relay when coolant temperature drops to approximately 101 °C (214 °F). When coolant temperature drops to 101 °C (214 ° F) the fan operates at low speed. The PCM de-energizes the low speed relay when coolant temperature drops to approximately 93 °C (199 °F). Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan operates at low speed. Fan Control Module The SSFR relay is located on the left front inner frame just behind the radiator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Temperature Sensor 7 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1778 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1779 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1780 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1781 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40° F to 265° F). The engine coolant temperature sensor provides an input voltage to the PCM. As coolant temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle speeds until normal operating temperatures are reached. The engine coolant sensor is also used for cooling fan control. Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1782 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant Temperature Sensor 1. With the key off, disconnect wire harness connector from coolant temperature sensor. Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter should read as follows: a. ECT STET at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1783 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core Heater Core: Service and Repair Front Heater Core REMOVAL 1. Drain coolant system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Service and Repair 2. Remove left side lower column cover. 3. Remove steering column assembly. Refer to: "Steering and Suspension : Steering : Steering Column : Service and Repair" See: Steering and Suspension/Steering/Steering Column/Service and Repair ABS Module 4. Remove ABS module, bracket and wiring. Interconnect And Bracket 5. Remove I/P to body harness interconnect and bracket. Lower Silencer Boot Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 1791 6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood. Heater Core Plate And Tubes 8. Remove heater core cover. Insert a small amount of towels under the heater core tubes. Remove heater core plate and tubes. Depress Clips 9. Depress heater core retaining clips. Accelerator Pedal 10. Pull up on accelerator pedal and slide heater core past. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 1792 Brake Pedal 11. Depress brake pedal and remove heater core from HVAC housing. INSTALLATION For installation, reverse the above procedures. Install screws to retain heater core in housing. Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 NM (27 ± 9 in. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 1793 Heater Core: Service and Repair Rear Heater Core REMOVAL 1. Remove the lower right quarter trim panel. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair Heater Core Lines 2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4. Carefully pull the heater core and tubes up and straight out of the unit. INSTALLATION Filling Heater Core For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall performance. NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be used: - Vehicle at room temperature. - Engine is brought up to operating temperature. - Front unit is OFF, temperature slides are at full HEAT position. - Engine is at idle. - With rear blower motor ON HIGH - Discharge air temperature measured at the dual register located on the C-pillar base, is between 57° C to 62° C (135° and 145° F). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Upper Heater Hose Lower Heater Hose 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Temperature Gauge: Initial Inspection and Diagnostic Overview Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1802 Temperature Gauge: Component Tests and General Diagnostics Temperature Gauge Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1803 Temperature Gauge Diagnosis (Part 2 Of 2) Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL CAUTION: Use of pliers on draincock is not recommended. Damage may occur to part. Draincock should not be removed unless leakage observed. Draincock Disassembled 1. Turn the draincock stem counterclockwise to unscrew the stem. When the stem is unscrewed to the end of the threads turn back 1/8 turn and pull the stem from the radiator tank. INSTALLATION 1. Push the draincock assembly body into the tank opening until it snaps into place. 2. Tighten the draincock stem by turning clockwise until it stops. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation The radiator is equipped with a pressure cap that releases excessive cooling system pressure, maintaining a range of 97-124 kPa (14-18 psi). Radiator Pressure Cap Filler Neck The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity. There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting allowing coolant to return to radiator from coolant reserve system tank by vacuum through connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the radiator hoses will be collapsed on cool down. Clean the vent valve and inspect coolant recovery hose routing, to ensure proper sealing when boiling point is reached. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Page 1814 Radiator Cap: Testing and Inspection RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK Radiator Pressure Cap Filler Neck The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple. Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold pressure at 55 kPa (8 psi) minimum. WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. There is no need to remove the radiator cap at any time except for the following purposes: 1. Check and adjust coolant freeze point. By adding or subtracting coolant through CRS bottle. 2. Refill system with new coolant. 3. Conducting service procedures. 4. Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY. WAIT 15 MINUTES BEFORE REMOVING CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN, ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS, PUSH DOWN AND REMOVE THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. PRESSURE TESTING RADIATOR CAP Dip the pressure cap in water, clean any deposits off the vent valve or its seat and apply cap to end of Radiator Pressure Tool. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace cap. Pressure Testing Radiator Cap If the pressure cap tests properly while positioned on Radiator Pressure Tool, but will not hold pressure or vacuum when positioned on the radiator. Inspect the radiator filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. CAUTION: Radiator Pressure Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Page 1815 INSPECTION Hold the cap in hand, right side up. The vent valve at the bottom of the cap should open. If the rubber gasket has swollen and prevents the valve from opening, replace the cap. Hold the cleaned cap in hand upside down. If any light shows between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold the vent shut. Replacement cap must be of the type designed for coolant reserve system with a completely sealed diaphragm spring, and rubber gasket to seal to filler neck top surface. This design assures coolant return to radiator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Spring Clamp Size Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. Hose Clamp Tool The hose clamps are removed by using Special Tool 6094 or equivalent constant tension clamp pliers to compress hose clamp. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. Make sure hoses and connectors are clean and dry before installation. Do not lubricate hoses when installing. Spring type hose clamps are used in all applications. If replacement is necessary, replace with the original Mopar(R) equipment spring type clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions Radiator Cooling Fan Motor Relay: Technical Service Bulletins Cooling System - Cooling Fan Relay Revisions NUMBER: 26-10-99B GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the cooling fan relay information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1824 7-1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1825 7-12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1826 7-25 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1827 7-25A Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1828 7-25B Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 1829 14-49 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1830 Radiator Cooling Fan Motor Relay: Locations Engine Compartment Connections - Early Build Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1831 Engine Compartment Connections - Late Build Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1832 Fan Control Module The SSFR (Solid State Fan Relay) is located on the left front inner frame just behind the radiator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 Radiator Cooling Fan Motor Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 A/C & Heater -- Sheet 8w-42-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 1854 Radiator Cooling Fan Motor Relay: Description and Operation SOLID STATE FAN RELAY-PCM OUTPUT The radiator fan runs at a variable speed depending on coolant temperature and A/C system pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR). A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR. Depending upon the amount of pulse on time, the SSFR puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 102 °C (215 °F) the PCM grounds the SSFR relay. If engine coolant reaches 207 °C (225 °F) the PCM grounds the high speed ground relay and high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and high speed ground relay when coolant temperature drops to approximately 101 °C (214 °F). When coolant temperature drops to 101 °C (214 ° F) the fan operates at low speed. The PCM de-energizes the low speed relay when coolant temperature drops to approximately 93 °C (199 °F). Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan operates at low speed. Fan Control Module The SSFR relay is located on the left front inner frame just behind the radiator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Temperature Sensor 7 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1860 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1861 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1862 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1863 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40° F to 265° F). The engine coolant temperature sensor provides an input voltage to the PCM. As coolant temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle speeds until normal operating temperatures are reached. The engine coolant sensor is also used for cooling fan control. Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1864 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant Temperature Sensor 1. With the key off, disconnect wire harness connector from coolant temperature sensor. Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter should read as follows: a. ECT STET at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1865 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Temperature Gauge: Initial Inspection and Diagnostic Overview Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1873 Temperature Gauge: Component Tests and General Diagnostics Temperature Gauge Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1874 Temperature Gauge Diagnosis (Part 2 Of 2) Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications THERMOSTAT OPERATING RANGE: Opening Temperature ......................................................................................................................... ...................................................................... 192°F Full Opening Temperature ................................. ...................................................................................................................................................... 220°F Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1881 Thermostat: Description and Operation THERMOSTAT The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88° to 93°C (192° to 199°F). They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the fan, the radiator, and the ambient temperature, not the thermostat. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1882 Thermostat: Service and Repair REMOVAL 1. Drain cooling system down below the thermostat level. Thermostat, Housing, And Water Box-3.3/3.8L Engines 2. Remove thermostat housing bolts and housing. 3. Remove thermostat. Discard gasket and clean both gasket sealing surfaces. INSTALLATION 1. Place a new gasket (dipped in water) on the thermostat housing surface, center thermostat into opening in the intake manifold water box. 2. Place housing and gasket over the thermostat, making sure thermostat is in the recess provided. 3. Install housing to intake manifold and tighten bolts to 28 Nm (250 inch lbs.). 4. Refill the cooling system to the proper level. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Torque Specs Torque Specs Thermostat Housing Bolts 250 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1889 Water Pump: Description and Operation The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain case cover, using an O-ring for sealing. It is driven by the back surface of the Poly-V Drive Belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1890 Water Pump: Testing and Inspection Replace the water pump if it has any of the following defects: 1. Damage or cracks on the pump body. 2. Coolant leaks: If the seal is leaking, this will be evident by traces of thick deposits of greenish-brown dried glycol running down the pump body and components below. A thin black stain below pump weep hole is considered normal operation. 3. Impeller rubs inside of chain case cover or cylinder block. 4. Excessively loose or rough turning bearing. NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1891 Water Pump: Service and Repair REMOVAL 1. Drain Cooling System. 2. Remove accessory drive belt. 3. Remove right front lower fender shield. 4. Remove water pump pulley bolts and remove pulley. Water Pump-3.3/3,8L Engines 5. Remove water pump mounting screws. Remove water pump. 6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface. INSTALLATION Water Pump Body 1. Install new O-ring into groove. 2. Install water pump to chain case cover. Tighten screws to 12 Nm (105 inch lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump. Install screws and tighten to 30 Nm (250 inch lbs.). 5. Install accessory drive belt. 6. Install right front lower fender shield. 7. Refill Cooling System. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation There is no regularly scheduled maintenance on any Chrysler catalytic converter. If damaged, the converter must be replaced. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country. The combustion reaction caused by the catalyst releases additional heat in the exhaust system. Causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel igniting when passing through the converter. The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan temperatures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1896 Catalytic Converter: Service and Repair WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. REMOVAL 1. Remove muffler and tailpipe assembly. Downstream Oxygen Sensor 2. Disconnect downstream oxygen sensor from the catalytic converter pipe. 3. Remove catalytic converter to exhaust manifold attaching fasteners. 4. Remove catalytic converter and gasket. INSTALLATION 1. Position new gasket onto manifold flange and install catalytic converter. Tighten fasteners to 28 Nm (250 inch lbs.). 2. Connect downstream oxygen sensor. 3. Install muffler and tailpipe assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Manifold to Cylinder Head Bolts ........................................................................................................................................................ 23 Nm (200 inch lbs.) Fastener ................................................................................................................ ............................................................................... 23 Nm (200 inch lbs.) Stud .................................. .............................................................................................................................................................. ..... 23 Nm (200 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL 1. Disconnect battery negative cable. 2. Remove accessory drive belt. 3. Remove generator. 4. Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at flex-joint. 5. Disconnect downstream oxygen sensor connector. 6. Lower exhaust system to gain access to rear manifold. EGR, Heated Oxygen Sensor And Generator/Power Steering Strut 7. Separate EGR tube from rear manifold and disconnect heated oxygen sensor lead wire. 8. Remove heat shield from rear engine mount. 9. Remove generator/power steering support strut. 10. Remove bolts attaching crossover pipe to manifold. 11. Disconnect up stream oxygen sensor connector. 12. Remove bolts attaching rear manifold to cylinder head and remove manifold. Heat Shield-Front 13. Lower vehicle and remove screws attaching front heat shield to front manifold. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1902 Crossover Pipe 14. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head. Remove assemblies. 15. Inspect and clean manifold. Refer to Cleaning and Inspection for procedures. INSTALLATION 1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.). 2. Install generator. NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. Replace if necessary. 3. Using new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 54 Nm (40 ft. lbs.). 4. Connect oxygen sensor lead. 5. Install EGR tube and generator/power steering strut. 6. Install front exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.). 7. Attach exhaust crossover with a new gasket and tighten fasteners to 54 Nm (40 ft. lbs.). 8. Connect up stream oxygen sensor connector. 9. Install exhaust system. 10. Attach exhaust pipe to exhaust manifold using new gasket and tighten bolts to 28 Nm (250 inch lbs.). 11. Connect downstream oxygen sensor connector. 12. Install front manifold heat shield and tighten attaching screws to 12 Nm (105 inch lbs.). 13. Install accessory drive belt. 14. Connect battery negative cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1903 Exhaust Manifold: Service and Repair Cleaning and Inspection INSPECTION Check Exhaust Manifold Mounting Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust cross-over mounting surface with a straightedge and thickness gauge. CLEANING Remove the gasket material from the manifold surfaces (if equipped). Be careful not to gouge or scratch the sealing surface. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Crossover Pipe Fange Fastners 25 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1907 Exhaust Pipe: Service and Repair WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. REMOVAL 1. Raise vehicle on hoist and apply penetrating oil to clamp bolts and nuts of component being removed. Band Clamp Exhaust System Components 2. Loosen clamps and supports and from exhaust system to permit alignment of parts during assembly. 3. When removing tailpipe, raise rear of vehicle to relieve body weight from rear springs to provide clearance between pipe and rear axle parts. 4. Clean ends of pipes or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. When replacement is required on any component of the exhaust system. It is important that original equipment parts (or their equivalent) be used; ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could effect emissions and performance. INSTALLATION 1. Assemble pipes, muffler support and clamp loosely to permit alignment of all parts. 2. Beginning at front of system, align and clamp each component to maintain position and proper clearance with underbody parts. 3. Tighten the clamp and support to the proper torques and clearances. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Muffler Hanger Support Clamp Fastener 150 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat Shield-Muffler Fastener 23 in.lb Heat Shield-Toe Board Fastener 23 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1914 Heat Shield: Description and Operation Heat Shields Heat shields are needed to protect both the vehicle and the floor pan from the high temperatures developed near the catalytic converter and muffler. Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Refer to Exhaust Pipe for procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions NUMBER: 26-12-99G GROUP: Miscellaneous DATE: December, 1999 THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the wiring schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1925 8W-44-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1926 8W-44-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1927 8W-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1928 8W-50-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1929 8W-50-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1930 8W-50-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1931 8W-80-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1932 8W-90-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1933 8W-90-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1934 Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1935 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1936 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1937 Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set NO: 18-25-98 GROUP: Vehicle Performance DATE: Aug. 14, 1998 SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code MODELS: 1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE. DISCUSSION: During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous "EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the ignition to the ON position and determine if each PRNDL indicator in the instrument cluster becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not necessary to replace the BCM. NOTE: CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL FAILURE IN THE PRNDL SYSTEM. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 1938 Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 1941 Junction Block, Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1945 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1946 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1947 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1948 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1949 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1950 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1951 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1952 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1953 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1954 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1955 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1956 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1957 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 Body Control Module: Connector Views Body Control Module C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 Body Control Module C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 Body Control Module Interconnect Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 Body Control Module: Electrical Diagrams BCM Block Diagram Wiring Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 Body Control Module -- Sheet 8w-45-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 Body Control Module -- Sheet 8w-45-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 Body Control Module -- Sheet 8w-45-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 Body Control Module -- Sheet 8w-45-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 Body Control Module -- Sheet 8w-45-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 Body Control Module -- Sheet 8w-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 Body Control Module -- Sheet 8w-45-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Body Control Module -- Sheet 8w-45-9 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 1975 Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 Body Control Module: Description and Operation Part 1 of 3 INTRODUCTION Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. This information will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not come on at all - warning lamp stays on BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: automatic door locks - battery protection - CCD radio - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 1978 - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar, ignition, RKE actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as described above. Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and glove box closed). Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened, The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 1979 Body Control Module: Description and Operation Part 2 of 3 COMPASS/MINI-TRIP COMPUTER The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. See the service procedure. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Compass Magnetic Variance Zones Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the following zone map provided. The number shown for your area is the variance number for your area. 1. Set the compass/mini-trip console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation, NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS. MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb check is performed. This consists of activating all CCD controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 1980 as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Programming an RKE Transmitter Customer Programming Method NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED. 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds. While still holding the unlock button, press the panic button, then release both buttons. The BCM will acknowledge that it has grounded the RKE module program enable wire by sounding a single chime tone. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition off. DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in Programming Mode" does not appear, exit and select "Program RKE" again. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, press "Back Page". RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 1981 Body Control Module: Description and Operation Part 3 of 3 VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE COMMUNICATIONS. Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system Will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 1982 System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all door are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Test - NOTE: System self-test can be entered only with the DRB. NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. WIPER SYSTEM Front The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned OFF the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. DRB III (R) ERROR MESSAGES Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User- Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 1983 DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition WARNINGS Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light GLOSSARY OF ACRONYMS ACM Airbag Control Module AECM Airbag Electronic Control Module (type of ACM) ASDM Airbag System Diagnostic Module (type of ACM) BCM body control module CAB controller antilock brake CCD Chrysler Collision Detection (vehicle communications bus) CMTC Compass/Mini-Trip Computer (module) DLC data link connector (previously called "engine diagnostic connector") DR driver HVAC heater, ventilation, air condition MET metric MIC mechanical instrument cluster MUX multiplexed ODO odometer PASS passenger PCM powertrain control module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 1984 PDC powertrain distribution center PTC positive temperature coefficient RKE remote keyless entry TCM transmission control module VF vacuum fluorescent display VTSS vehicle theft security system Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures AM/FM Switch Inoperative SYMPTOM * AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Joystick Inoperative SYMPTOM * BALANCE JOYSTICK INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Cassette Error SYMPTOM CASSETTE ERROR POSSIBLE CAUSES - Cassette Error / Replace radio CD Eject Switch Inoperative SYMPTOM * CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Error SYMPTOM CD ERROR POSSIBLE CAUSES - Defective radio Equalizer Inoperative SYMPTOM * EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - Radio/CD cable loose/disconnected - DIN cable data bus (CAV 1) open - DIN cable data bus (CAV 3) open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1987 - DIN cable terminals shorted - DIN signal wires (CAVS 2, 4, and 5) open - DIN fused B(+) circuit open - DIN fused ignition switch output circuit open - DIN ground circuit open - DIN metal connectors open - Radio defective - Radio input control defective FF/RW Switch Inoperative SYMPTOM * FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM * HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12V output circuit defective, open - Radio ground circuit defective, open - Power relay output circuit defective, open - Radio 12V output circuit shorted to ground - Radio choke defective - Speaker power relay defective, open - Speaker power relay defective, open - Junction block defective, open circuit - Defective radio - Radio choke output circuit defective, open - Radio output circuits defective No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Door or quarter speaker (+) circuit defective, open - Door or quarter speaker (-) circuit defective, open - Door or quarter speaker (+) circuit open - Door or quarter speaker (-) circuit open - Instrument panel or pillar speaker (+) circuit open - Instrument panel or pillar speaker (-) circuit open - Door or quarter speaker defective - Speaker defective, no response Pause/Play Switch Inoperative SYMPTOM * PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1988 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector defective - Antenna connections defective - Hood ground defective - Ground circuit defective, open - Radio connectors not properly connected - Ignition / alternator system noise - Radio defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Ground circuit open - Instrument panel - pillar speaker defective - Radio choke output circuit open - Speaker (+) and (-) circuits shorted together - Inoperative speaker defective PWR Switch Inoperative SYMPTOM * PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Radio Error SYMPTOM RADIO ERROR POSSIBLE CAUSES - Defective radio Remote Controls Inoperative SYMPTOM * REMOTE CONTROLS INOPERATIVE POSSIBLE CAUSES - No response, CCD bus failure - Radio control harness defective, open - Radio control MUX circuit shorted - Remote control switch defective - MUX control clockspring defective - Radio control ground circuit to BCM open - Radio control MUX circuit open - Radio MUX control circuit defective - Body Control Module defective Scan Switch Inoperative SYMPTOM * SCAN SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1989 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM * SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Set Switch Inoperative SYMPTOM * SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Left door speaker shorted - Left front instrument panel speaker shorted - Right door speaker shorted - Right front instrument panel speaker shorted - Right front (-) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (+) circuit shorted to ground - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left door speaker defective, shorted - Left front instrument panel speaker defective, shorted - Left quarter speaker shorted - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear speaker shorted - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Right rear quarter speaker shorted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1990 - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear quarter speaker shorted - Left rear speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Right rear pillar speaker shorted - Radio output circuits defective Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right channel speaker shorted - Right instrument panel speaker defective, shorted - Right front (+) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (-) circuit shorted to ground - Right pillar speaker shorted - Right quarter speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Radio output circuits defective Tape Eject Switch Inoperative SYMPTOM * TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Tune Switch Inoperative SYMPTOM * TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM * VOL/TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM * 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1991 Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - BCM fails chime test Chime Inoperative With Driver Seat Belt Unfastened SYMPTOM * CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Ground circuit to left seat belt switch connector open - Left seat belt switch open - BCM not responding to belt switch - Body Control Module seat belt switch sense open - Seat belt switch sense circuit open Chime Inoperative With Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition Switch - key in switch shorted - BCM - no chime response - head/park lamps ON - BCM - key in sense shorted default - BCM - no response to park lamp switch - Chime inoperative with exterior lamps ON Chime Inoperative With Key In Ignition & Driver Door Open SYMPTOM * CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Ignition switch ground circuit open - Key in ignition switch sense circuit open - Ignition switch - key in switch open - BCM - no chime to key in ignition - BCM not responding to key in switch Chime Inoperative With L or R Turn Signal On For 1 Mile SYMPTOM * CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE POSSIBLE CAUSES - Junction block - Left turn signal open - Junction block - Right turn signal open - BCM - no response to turn signal - BCM fails speed test - Chime - speedometer problem - Chime inoperative - turn signal on for 1 mile Chime Inoperative With Low Oil Pressure SYMPTOM Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1992 * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With the Dome Lamps On SYMPTOM * CHIME INOPERATIVE WITH THE DOME LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM failed - door open & key out default - BCM - key in switch sense shorted default Chime Sounds With Driver Door Open & Key Out SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM - key in switch sense shorted default - BCM not responding to key out Chime Sounds With Driver Seat Belt Fastened SYMPTOM * CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch sense circuit shorted to ground - Left seat belt switch shorted - BCM - no response to seat belt fastened - BCM seat belt switch input shorted to ground Auto Headlamps Will Not Turn Off SYMPTOM * AUTO HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - No response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Auto headlamp signal circuit shorted to ground - Electrochromic mirror defective - sensor stuck ON (default) - BCM defective - auto headlamp sensor stuck ON Auto Headlamps Will Not Turn On SYMPTOM * AUTO HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - NO response (BCM) - CCD bus failure - NO response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Electrochromic mirror defective (default) - BCM defective - auto headlamp sensor Fog Lamps Will Not Turn Off SYMPTOM * FOG LAMPS WILL NOT TURN OFF Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1993 POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp switched ground circuit shorted to ground - Headlamp switch defective - foglamp switched ground Fog Lamps Will Not Turn On SYMPTOM * FOG LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp bulbs open - Fog lamp relay control circuit open - Fog lamp relay output circuit open - Fog lamp relay defective, open - Multifunction dimmer switch defective (open) default - Fog lamp switched ground circuit open - BCM defective - Headlamp relay control - Multifunction switch defective (fog lamp relay control) default - Headlamp relay control circuit (foglamps) open Headlamps Will Not Turn Off SYMPTOM * HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch sense circuit shorted to ground - Headlamp relay control circuit shorted to ground - Low beam relay control circuit shorted to ground - Low beam relay control circuit (QUAD) shorted to ground - Low beam headlamp relay (QUAD) defective, shorted - Low beam headlamp relay defective (shorted) by default - PDC defective (low beam headlamp relay connector shorted) - Headlamp switch defective - switch sense - BCM defective (headlamp switch sense function) by default - BCM defective (low beam relay control shorted) by default Headlamps Will Not Turn On SYMPTOM * HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Both low beam fuses open - Fused low beam output circuit open (both lamps inoperative) - Fused low beam output circuit open (one lamp inoperative) - Headlamp defective (by default) - Headlamp fuse open - Headlamp switch sense circuit open - Headlamps defective (by default) - Multifunction switch defective (default) - Headlamp relay control circuit open - Low beam relay control circuit (Chrysler) open - Low beam relay control circuit open - Low beam headlamp relay defective (by default) - Low beam relay defective - relay control function - PDC defective - B(+) circuit at low beam fuse terminal - Power Distribution Center defective (low beam relay CAV A) - Power Distribution Center defective (low beam relay CAV B) - Headlamp switch defective (by default) - BCM defective - headlamp switch sense function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1994 - BCM defective - headlamp switch sense stuck open - BCM defective - low beam relay control open Park Lamps Will Not Turn Off SYMPTOM * PARK LAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Park lamp relay control circuit shorted to ground - Park lamp relay output circuit shorted to voltage - Park lamp switch sense circuit shorted to ground - Park lamp relay defective - control shorted (by default) - Headlamp switch defective - shorted - BCM defective - park lamp switch sense closed (by default) Park Lamps Will Not Turn On SYMPTOM * PARK LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Fused park lamp output circuit open - Park lamp bulb defective (by default) - Park lamp fuse in PDC open - Both park lamp fuses open - Park lamp fuse open - Park lamp relay control circuit open - Park lamp relay output circuit open - Park lamp switch sense circuit open - Park lamp relay defective (control function) - PDC defective - other B(+) cavity - PDC defective - park lamp relay connector, fused B(+) - Headlamp switch defective - park lamps (by default) - BCM defective - park lamp switch sense stuck open - BCM defective - park lamp switch sense function - BCM defective - parklamp control function (by default) ABS Warning Lamp SYMPTOM * ABS WARNING LAMP POSSIBLE CAUSES - BCM connector observable defect - CAB connector observable defect - Fused ignition switch output circuit open - ABS warning lamp defective - ABS warning lamp driver circuit open - ABS warning lamp driver circuit shorted to ground - ABS warning lamp flashing - BCM defective - CAB defective Airbag Warning Lamp SYMPTOM * AIRBAG WARNING LAMP POSSIBLE CAUSES - Airbag warning lamp failure All Warning Lamps Out SYMPTOM * ALL WARNING LAMPS OUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1995 POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Information Center defective Engine Temperature Warning Lamp SYMPTOM * ENGINE TEMPERATURE WARNING LAMP POSSIBLE CAUSES - Engine temperature lamp staying on - Temperature lamp not working - Engine temperature lamp/bulb defective - Fused ignition switch output circuit open - Defective BCM - Engine temperature warning lamp driver circuit open - Temperature warning lamp driver circuit shorted to ground - Information Center defective - Body Control Module defect - Defective Information Center High Beam Indicator Lamp SYMPTOM * HIGH BEAM INDICATOR LAMP POSSIBLE CAUSES - Headlamps inoperative - Fused right highbeam output circuit open - Ground circuit open - High beam indicator bulb defective - Defective Information Center Low Oil Pressure Warning Lamp SYMPTOM * LOW OIL PRESSURE WARNING LAMP POSSIBLE CAUSES - Oil pressure low - Oil warning lamp/bulb defective - Oil level low - Defective oil pressure switch - Oil pressure switch sense circuit shorted to ground - Oil pressure switch sense circuit open - Oil pressure switch defective - BCM defective - Defective Information Center Red Brake Warning Lamp SYMPTOM * RED BRAKE WARNING LAMP POSSIBLE CAUSES - Park brake pedal problem - Vehicle equipped antilock brakes - Brake fluid level low - Red brake warn lamp/bulb defective - Ground circuit open - Brake fluid level switch defective - Defective ignition switch - Defective park brake switch - Red brake warning lamp circuit open - Red brake warning lamp circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1996 - Information Center faulty - Ignition switch defective - Red brake warning lamp driver circuit open - Red brake warning lamp driver circuit faulty Service Engine Soon Lamp SYMPTOM * SERVICE ENGINE SOON LAMP POSSIBLE CAUSES - DTC's are present - Bulb & socket defective - Service Engine Soon indicator lamp driver circuit open - Service Engine Soon indicator lamp circuit shorted to ground - Defective Information Center circuit board - Powertrain Control Module defective Turn Signal Indicator Lamp SYMPTOM * TURN SIGNAL INDICATOR LAMP POSSIBLE CAUSES - Turn signal lamps inoperative - Ground circuit open - Left turn signal circuit open - Right turn signal circuit open - Turn signal bulbs defective - Junction Block defective - BCM defective - Information Center defective Vehicle Theft Alarm Indicator SYMPTOM * VEHICLE THEFT ALARM INDICATOR POSSIBLE CAUSES - Vehicle theft alarm indicator defective All Gauges Inoperative SYMPTOM * ALL GAUGES NOT OPERATING POSSIBLE CAUSES - BCM instrument cluster circuit output defective - Instrument Cluster PC board defective - DRB shows ignition unlock closed - No response - CCD bus instrument cluster - Body computer odometer failure - RAM test failure - ROM test failure Cluster Illumination SYMPTOM * CLUSTER ILLUMINATION POSSIBLE CAUSES - No response - CCD bus instrument cluster - Headlamp switch ground circuit defective - Inoperative lamp defective - Headlamp switch defective - Junction block defective - Dimmer switch signal circuit open - Dimmer switch signal circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1997 - Instrument panel lamps driver circuit shorted to ground - Panel lamps driver circuit open - Park lamps not lighting - Instrument Cluster circuit board defective - BCM dimmer switch signal circuit output faulty - BCM defective - BCM defective by default - Body computer odometer failure - BCM dimmer switch signal circuit defective - Illumination panel fuse OK - Inoperative lamp ground circuit - RAM test failure - ROM test failure Cluster Warning Lamps Odometer and PRNDL Display SYMPTOM * CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY POSSIBLE CAUSES - Any one lamp/bulb defective - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Body computer odometer failure DTC - No response - CCD bus instrument cluster - Washer fluid level switch defective - BCM washer fluid switch sense circuit input defective - All segments fail to light - Faulty odometer and PRNDL lamp - Generator lamp failure - Instrument cluster printed circuit board defective Gauges Not Returning to Zero With Key Off SYMPTOM * GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF POSSIBLE CAUSES - Fused B(+) circuit open - No response - CCD bus instrument cluster - Instrument Cluster PC board defective - Body computer odometer failure - RAM test failure - ROM test failure One Gauge Not Operating Properly SYMPTOM * ONE GAUGE OPERATING IMPROPERLY POSSIBLE CAUSES - DRB reads active on the bus - DRB reads no vehicle speed sense signal code - IOD fuse is loose in junction block - Speedometer calibration out - Any one lamp/bulb defective - DRB reading not matching RPM - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Washer fluid level switch defective - Gauge pack defective - Speedometer/Odometer gauge pack defective - Tachometer calibration out - Cooling system condition faulty - DRB reads coolant temperature sensor code Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1998 - DRB reads engine temperature accurately - BCM instrument cluster circuit output defective - Body Control Module defective - Gauge pack defective - Instrument Cluster printed circuit board defective - DRB shows ignition unlock closed - BCM washer fluid level switch sense circuit input defective - All segments fail to light - BCM temperature gauge input defective - Faulty odometer and PRNDL lamp - Generator lamp failure - PCM defective - Pinion factor failure Trip and Rest Button(S) SYMPTOM * TRIP AND RESET BUTTON(S) POSSIBLE CAUSES - Trip & reset button(s) defective Courtesy Lamps Inoperative W/Dome Lamp Switch SYMPTOM * COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH POSSIBLE CAUSES - Courtesy lamp switch sense circuit open - Headlamp switch defective - courtesy lamp function open - BCM defective - courtesy lamp switch sense (by default) - BCM defective - dome lamp switch function Courtesy Lamps Inoperative With Any Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH ANY DOOR POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay control circuit open - Switched courtesy lamp relay control circuit open - Junction block defective - lamp relay fused B(+) (CAV 87) open - Courtesy lamp relay defective - coil open - Junction block defective - lamp relay fused B(+) (CAV 30) open - Junction block defective - lamp relay fused B(+) (CAV 86) Open - Headlamp switch defective - open - BCM defective - lamp relay control function (by default) - BCM defective - driver door ajar switch status Courtesy Lamps Inoperative With Driver Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR POSSIBLE CAUSES - Driver door ajar switch defective, open - Driver door ajar switch sense circuit open - Left front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Left Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR POSSIBLE CAUSES - Left sliding door ajar switch sense circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1999 - Left sliding door ajar ground circuit open - Left sliding door ajar switch defective, open - BCM defective Courtesy Lamps Inoperative With Liftgate SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LIFTGATE POSSIBLE CAUSES - Liftgate ground circuit open - Liftgate ajar switch open - ajar switch disconnected - Liftgate ajar switch sense circuit open - BCM defective, open Courtesy Lamps Inoperative With Passenger Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR POSSIBLE CAUSES - Passenger door ajar switch defective, open - Passenger door ajar switch sense circuit open - Right front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Right Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR POSSIBLE CAUSES - Right sliding door ajar switch defective, open - Right sliding door ajar switch sense circuit open - Right sliding door ajar ground circuit open - BCM defective, open Courtesy Lamps On at All Times SYMPTOM * COURTESY LAMPS ON AT ALL TIME POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay output circuit shorted to B(+) - Courtesy lamp relay control circuit shorted to ground - Switched courtesy lamp relay control circuit shorted to ground - Courtesy lamp relay defective - coil shorted - Headlamp switch shorted - BCM defective - relay control shorted (by default) Illuminated Entry Inoperative With Driver Door Key Cylinder SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER POSSIBLE CAUSES - Driver door key switch unlock position stuck - Driver door key cylinder switch defective - Driver door key switch sticking Illuminated Entry Inoperative With RKE Transmitter SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2000 - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective unlock switch - RKE module default replacement - RKE module defective CMTC Avg MPH/Fuel Economy Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR WRONG POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative CMTC Elapsed Time Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective BCM / Indicator lights CMTC Fails to Respond to Instrument Cluster Dimming SYMPTOM * COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Trip Odometer Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE/WRONG. POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative Compass/Mini-Trip Computer Displaying OC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING OC POSSIBLE CAUSES - Open sensor ground circuit - Ambient Temperature Sensor defective - Open Ambient Temperature Sensor signal circuit - Defective Compass/Mini-Trip Module - sensor ground circuit. Compass/Mini-Trip Computer Displaying SC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING SC POSSIBLE CAUSES - Defective Ambient Temperature Sensor - Ambient Temperature Sensor signal circuit shorted to ground - Compass/Mini-Trip Module default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2001 Compass/Mini-Trip Computer Segments Fail to Light SYMPTOM * COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - segments fail to light Compass/Mini-Trip Computer Shows Failed SYMPTOM * COMPASS/MINI-TRIP COMPUTER SHOWS FAILED POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - shows failed Compass/Mini-Trip Computer Switch Inoperative SYMPTOM * COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Incorrect Ambient Temperature Readings SYMPTOM * INCORRECT AMBIENT TEMPERATURE READINGS POSSIBLE CAUSES - Open sensor ground - defective CMTM - Sensor ground circuit partial short to ground - Defective Ambient Temperature Sensor/Road test - Ambient Temperature Sensor signal circuit partial short - Ambient Temperature Sensor signal circuit shorted - Defective Compass/Mini-Trip Module - Defective Compass/Mini-Trip Module sensor ground circuit Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH POSSIBLE CAUSES - Junction block defective - Door unlock relay output circuit open - Door unlock relay output circuit resistance low Additional All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door unlock relay control inoperative at BCM - Door unlock relay defective - Door unlock relay coil resistance out of tolerance - Door unlock relay output circuit shorted to ground Additional All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2002 POSSIBLE CAUSES - Passenger door switch MUX shorted to battery - Door lock switch resistance high in unlock position - Driver door switch MUX circuit shorted to battery - Liftgate switch MUX shorted to battery - BCM door lock relay control circuit inoperative - Liftgate switch MUX at BCM defective - Door lock relay control ground circuit open - Door lock relay defective - Fuse # 26 defective - Fused B(+) circuit open - Fused B(+) circuit shorted to ground - Ground circuit open at door lock relay connector Additional All Doors Fail to Lock and Unlock From One Switch SYMPTOM ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH POSSIBLE CAUSES - Door key cylinder switch connector circuit ground circuit open - Door key cylinder switch defective - Liftgate key cylinder switch defective - Liftgate switch MUX shorted to battery - Door switch MUX circuit to BCM open - Driver door switch MUX circuit open at BCM connector - Liftgate switch MUX circuit open at BCM connector - Liftgate switch MUX circuit to BCM open - Passenger door switch MUX circuit open at BCM connector - Passenger door switch MUX circuit to BCM open - Door lock switch connector ground circuit open - Door lock switch defective - Door lock switch MUX circuit open - Door locks inoperative from key cylinder switch - Door switch MUX circuit shorted to battery Additional All Doors Failing to Lock From Any Switch SYMPTOM ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door lock relay control circuit from BCM fails - Key - in ignition switch circuit to BCM defective - Door lock relay does not operate - Door lock relay coil resistance out of tolerance - Door lock relay output shorted to ground - Ignition switch defective - Key - in ignition switch sense circuit shorted to ground Additional Driver Door (w/RKE) Failing to Unlock From Any SW SYMPTOM ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Driver door unlock relay coil resistance out of tolerance - Driver door unlock relay defective - Driver door unlock relay output circuit shorted to ground - Voltage too low at junction block fused B(+) circuit Additional One Door Fails to Lock and Unlock From Any Switch SYMPTOM ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2003 POSSIBLE CAUSES - RKE equipped door lock fails to lock & unlock - Door lock motor defective - Driver unlock relay ground open in junction block - Door lock relay output circuit open - Door unlock relay output circuit open - Driver door unlock relay open All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective door unlock switch - RKE module default replacement - RKE module defective All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Defective door lock switch - Defective unlock switch All Doors Fail to Lock and Unlock From One Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Lock From Any Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2004 - Defective unlock switch All Doors Failing to Lock From One Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Unlock From One Switch SYMPTOM * ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Automatic Door Locks Do Not Lock Over 15 MPH SYMPTOM * AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH POSSIBLE CAUSES - Link to body communication bus inoperative - TPS malfunction causes door lock problem - VSS malfunction causes door lock problem - Auto door lock not enabled Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - BCM defective - BCM sends wrong key - in ignition status - BCM a connector terminals damaged - Ignition switch open - Key - in ignition switch ground circuit open - Key - in ignition switch sense circuit open Driver Door (w/RKE) Failing to Unlock From Any Switch SYMPTOM * DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch One Door Fails to Lock and Unlock From Any Switch SYMPTOM * ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2005 This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Remote Keyless Entry Problem SYMPTOM * RKE PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - RKE module default replacement - RKE module defective Front Wiper Operating Constantly W/Switch In Off Position SYMPTOM * FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION POSSIBLE CAUSES - Front wiper ON/OFF relay control circuit shorted to ground - Defective wiper ON relay/substitute relay - Defective multifunction switch/voltage - High/Low wiper relay HI speed output circuit shorted to voltage - High/Low wiper relay LO speed output circuit shorted to voltage - Defective BCM - 100 ohms default Front Wipers Not Parking In Off Position SYMPTOM * FRONT WIPERS NOT PARKING IN OFF POSITION TEST NOTE This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN POSSIBLE CAUSES - Wiper park switch toggle closed/open - Open wiper park switch sense circuit - Defective BCM - wiper park switch - Defective wiper motor/wiper park switch Front Wipers Not Working at All SYMPTOM * FRONT WIPERS NOT WORKING AT ALL POSSIBLE CAUSES - Open wiper on relay control circuit - BCM/wiper relay - Defective wiper ON relay - BCM/ground - Front wiper switch MUX circuit shorted to ground - Open front wiper switch MUX circuit between switch and BCM - Defective High/Low wiper relay - relay connector - Defective multifunction switch/front wiper switch - High/Low wiper relay HI speed output circuit shorted to ground - High/Low wiper relay LO speed output circuit shorted to ground - Open ground circuit/lights - Open High/Low relay LO speed output circuit between High/Low relay and wiper motor - Open fused ignition switch output circuit/multifunction switch - Defective Power Distribution Center - relay connector Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2006 - Defective Power Distribution Center - front wiper relay - Defective Power Distribution Center - wiper ON relay - Defective Power Distribution Center - wiper relay - Defective Power Distribution Center - H/L relay - Defective Power Distribution Center - B(+) circuit. - Defective wiper motor/harness - Defective BCM/wiper relay - Defective BCM/front wiper MUX - Defective BCM/sensors - Defective wiper motor ground circuit. Front Wipers Not Working In High Speed Mode SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE POSSIBLE CAUSES - Open HI/LO wiper relay control circuit - Defective HI/LO wiper RELAY - Wiper switch - Open wiper HI/LO relay HI speed output circuit - Defective multi - FUNCT switch/ ground circuit - Defective power DIST CNTR-H/L WPR RLY - Defective wiper Motor/HI speed output circuit - Open ground circuit/Multi - Function switch Front Wipers Not Working In Intermittent Mode SYMPTOM * FRONT WIPERS NOT WORKING IN INTERMITTENT MODE POSSIBLE CAUSES - Defective multifunction switch/positions - Defective BCM/wiper positions - Defective multifunction switch/Default Front Wipers Not Working In Low Speed Mode SYMPTOM * FRONT WIPERS NOT WORKING IN LOW SPEED MODE POSSIBLE CAUSES - High/Low wiper relay control circuit shorted to ground - Defective High/Low wiper relay - fused ignition switch - Open High/Low wiper relay - LO speed output circuit - Defective wiper motor/LO speed output circuit Rear Washer Motor Inoperative SYMPTOM * REAR WASHER MOTOR INOPERATIVE POSSIBLE CAUSES - Open rear washer motor control circuit - Defective rear washer motor/jumper - Open fused ignition switch output circuit/voltage - Defective HVAC Control Module / 3.8 volts - Defective BCM - washer motor operate Rear Wiper Not Parking In the Off Position SYMPTOM * REAR WIPER NOT PARKING IN THE OFF POSITION POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective HVAC Control Module/switch indicator lights - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2007 - Defective BCM/washer motor run - Defective BCM/cycle on default - Defective BCM/rear wiper switch voltage - Defective rear wiper motor/test light Rear Wiper Not Working at All SYMPTOM * REAR WIPER NOT WORKING AT ALL POSSIBLE CAUSES - Open rear wiper motor control circuit - Open rear wiper switch MUX circuit - Open ground circuit/rear wiper motor - Open fused ignition switch output circuit/fuse # 6 - Open fused ignition switch output circuit/fuse # 8 - Shorted fused ignition switch output circuit/fuse # 6 - Defective rear wiper motor/motor control - Defective HVAC Control Module/default - Defective HVAC Control Module/rear wiper switch MUX - Defective BCM/rear wiper switch MUX - Defective BCM/rear wiper motor - Defective HVAC Control Module/21-Way connector Rear Wiper Not Working In the Intermittent Mode SYMPTOM * REAR WIPER NOT WORKING IN THE INTERMITTENT MODE POSSIBLE CAUSES - Defective rear wiper motor/intermittent switch - Defective HVAC Control Module/indicator light - Defective HVAC Control Module/rear wiper switch - Defective BCM/test light default Rear Wiper/Wash Working Continuously SYMPTOM * REAR WIPER/WASH WORKING CONTINUOUSLY POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default - Defective BCM/washer motor run - Defective BCM/rear wiper switch voltage Wiper/Wash Function Not Working Properly SYMPTOM * WIPER/WASH FUNCTION NOT WORKING PROPERLY POSSIBLE CAUSES - Defective washer motor/washer pump control - Operate wipers - Open washer pump control circuit - Defective multifunction switch/washer pump control - Open fused ignition switch output circuit - Defective junction block/BCM - Defective junction block/block connector - Defective BCM/junction block - Defective BCM/stalk switch - Fused ignition switch output circuit shorted to ground - Open washer pump control circuit/multifunction switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2008 Body Control Module: Component Tests and General Diagnostics Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2009 Body Control Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2010 Body Control Module: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) Body Control Module - Location 4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Refer to Instrument Panel and Systems, Body Control Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2011 Body Control Module: Tools and Equipment DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Power Distribution Center & Powertrain Control Module (PCM) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 Powertrain Control Module C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2037 Powertrain Control Module: Description and Operation OPERATION Powertrain Control Module The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet changing engine operating conditions. During the crank-start period the PCM advances ignition timing a set amount. During engine operation, the amount of spark advance provided by the PCM is determined by the following input factors: available manifold vacuum - barometric pressure - engine coolant temperature - engine RPM - throttle position The PCM also regulates the fuel injection system. Refer to the Fuel Injection. The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2038 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection Power Distribution Center Retaining Screws 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket. Battery Heat Shield 3. Remove heat shield from battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2039 Battery Clamp 4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle. PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2040 PCM 40-way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both way connectors. PCM Removal/Installation 9. Remove 3 screws holding PCM to fender. 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2044 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2066 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2067 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2070 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 2071 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2076 Power Distribution Center -- Sheet 8w-10-2 The fuel pump relay is located in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2077 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2078 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit contains a 9 amp fuse. The fuse is located in the PDC. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2079 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2080 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2084 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2106 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2107 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2110 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 2111 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation OPERATION The temperature sensor, in the PCM, is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2120 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2121 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2122 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2123 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2124 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2125 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2126 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Temperature Sensor 7 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2130 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2131 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2132 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2133 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40° F to 265° F). The engine coolant temperature sensor provides an input voltage to the PCM. As coolant temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle speeds until normal operating temperatures are reached. The engine coolant sensor is also used for cooling fan control. Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2134 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant Temperature Sensor 1. With the key off, disconnect wire harness connector from coolant temperature sensor. Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter should read as follows: a. ECT STET at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2135 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2139 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2140 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2141 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2142 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2143 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2144 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The level sensor is attached to the side of the fuel pump module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2148 Fuel Level Sensor: Description and Operation DESCRIPTION The level sensor is attached to the side of the fuel pump module. The level sensor consists of a float, an arm, and a variable resistor. OPERATION As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2149 Fuel Level Sensor: Testing and Inspection This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Level Sensor Diagnosis The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2150 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector. NOTE: The pump module harness on TOP of flange is not serviceable or removable. Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2151 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Level Sensor Removal/Installation 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2152 Groove In Back Side Of Level Sensor 2. Wrap wires into groove in back of level sensor. Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2156 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2157 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2158 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2159 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Sensor Tightening Torque 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2163 MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2164 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2165 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. MAP Sensor MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2166 MAP Sensor The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The sensor connects electrically to the PCM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2167 Manifold Pressure/Vacuum Sensor: Testing and Inspection To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. MAP Sensor Connector 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3. With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (± 0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If not OK, repair or replace the wire harness as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2168 Manifold Pressure/Vacuum Sensor: Service and Repair Map Absolute Pressure Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the intake manifold. INSTALLATION 1. Reverse the above procedure for installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Oxygen Sensor 27 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2174 Oxygen Sensor: Locations Oxygen Sensor(s) Heated Oxygen Sensor Downstream Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2175 Oxygen Sensor: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2176 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2177 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2178 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR Heated Oxygen Sensor Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2179 Heated Oxygen Sensor The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2180 Oxygen Sensor: Testing and Inspection Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical connector from each oxygen sensor. The white wires in the sensor connector are the power and ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement REMOVAL 1. Raise and support vehicle. WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. Oxygen Sensor Grommet Cover 2. Remove grommet cover to expose connector. Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector. Oxygen Sensor Removal/Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2183 INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2184 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Upstream Heated Oxygen Sensor The oxygen sensor is installed in the exhaust manifold . CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2188 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2189 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2190 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2191 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2192 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 2197 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 2198 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2199 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2200 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2201 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2202 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2203 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2227 Vehicle Speed Sensor: Description and Operation Description The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are threaded into the transaxle case and are considered primary inputs to the Trans- mission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2232 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2233 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2234 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2235 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2236 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2241 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2242 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2243 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2244 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2245 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2246 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2247 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2251 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2252 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2253 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2254 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2255 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2256 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 2266 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 2272 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 2273 Ignition Switch Lock Cylinder: Description and Operation DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION Ignition Lock Cylinder Detents The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 2274 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 2275 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2279 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2280 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2281 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2282 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Key On, Engine Off .............................................................................................................................. ......................................... (approx.) 338 kPa (49 psi) Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2288 Fuel Pressure: Capacity Specifications Information not supplied by the manufacturer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2292 Idle Speed: Testing and Inspection 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. PCV Valve 4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6. Air Metering Fitting 6457 a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b. Disconnect the idle purge line from the throttle body nipple. 7. a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector. 8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 10. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum air-flow is set correctly. IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above 1000 Miles = 575-875 RPM 12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2293 b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle purge line. 16. Remove DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Air Inlet Resonator 1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves together. Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2298 Air Cleaner Element 4. Remove element from air cleaner housing. INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2303 Fuel Pressure Release: Service and Repair WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. Fuel Pressure Test Port Releasing Fuel Pressure 3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. 5. Replace Pressure test port cap when finished doing pressure test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable = Maximum Resistance #1 = 18.5 K Ohms #2 = 15.5 K Ohms #3 = 20.4 K Ohms #4 = 21.2 K Ohms #5 = 27.7 K Ohms #6 = 26.7 K Ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2314 Ignition Cable: Description and Operation DESCRIPTION The spark plug cables and spark plug boots are made from high temperature silicon materials. The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. They also identify proper heat shield installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The bottom of the spark plug heat shield must make contact with the spark plug hex. The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2315 Ignition Cable: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. Spark Plug Cables # 3 And # 5 REMOVAL 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 3. Remove the cable from the retaining bracket. Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. Spark Plug Cable # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove the cable from the retaining bracket. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2319 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2320 Spark Plug: Description and Operation SPARK PLUGS RESISTER DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Setting Spark Plug Electrode Gap Refer to the Specifications for gap and type of spark plug. SPARK PLUGS PLATINUM DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule. All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads The spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions per schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both electrode ends as shown. Extreme care must be used to prevent spark plug cross threading, mis-gaping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2321 Spark Plug: Testing and Inspection Spark Plug Condition Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Normal Operating Conditions Normal Operation And Cold (Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and then reinstalled. CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones. Oil Or Ash Encrusted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2322 Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Electrode Gap Bridging Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Scavenger Deposits Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2323 Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. Spark plugs with chipped electrode insulators must be replaced. Preignition Damage Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2324 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2325 Spark Plug: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation Use extreme care when removing and installing the spark plug cables. The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly Spark Plug # 3 AND # 5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator]ator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. Spark Plug # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure: Minimum 100 psi with no more than 25% variance between cylinders. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2329 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators: fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System, disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. Refer to Powertrain Management for Specifications. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation OPERATION The temperature sensor, in the PCM, is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions NUMBER: 26-12-99G GROUP: Miscellaneous DATE: December, 1999 THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the wiring schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2341 8W-44-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2342 8W-44-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2343 8W-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2344 8W-50-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2345 8W-50-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2346 8W-50-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2347 8W-80-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2348 8W-90-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2349 8W-90-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2350 Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2351 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2352 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2353 Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set NO: 18-25-98 GROUP: Vehicle Performance DATE: Aug. 14, 1998 SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code MODELS: 1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE. DISCUSSION: During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous "EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the ignition to the ON position and determine if each PRNDL indicator in the instrument cluster becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not necessary to replace the BCM. NOTE: CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL FAILURE IN THE PRNDL SYSTEM. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2354 Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2357 Junction Block, Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2375 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 Body Control Module: Connector Views Body Control Module C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 Body Control Module C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 Body Control Module Interconnect Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 Body Control Module: Electrical Diagrams BCM Block Diagram Wiring Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 Body Control Module -- Sheet 8w-45-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 Body Control Module -- Sheet 8w-45-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 Body Control Module -- Sheet 8w-45-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 Body Control Module -- Sheet 8w-45-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Body Control Module -- Sheet 8w-45-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Body Control Module -- Sheet 8w-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 Body Control Module -- Sheet 8w-45-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Body Control Module -- Sheet 8w-45-9 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 2391 Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 Body Control Module: Description and Operation Part 1 of 3 INTRODUCTION Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. This information will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not come on at all - warning lamp stays on BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: automatic door locks - battery protection - CCD radio - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2394 - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar, ignition, RKE actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as described above. Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and glove box closed). Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened, The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2395 Body Control Module: Description and Operation Part 2 of 3 COMPASS/MINI-TRIP COMPUTER The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. See the service procedure. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Compass Magnetic Variance Zones Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the following zone map provided. The number shown for your area is the variance number for your area. 1. Set the compass/mini-trip console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation, NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS. MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb check is performed. This consists of activating all CCD controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2396 as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Programming an RKE Transmitter Customer Programming Method NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED. 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds. While still holding the unlock button, press the panic button, then release both buttons. The BCM will acknowledge that it has grounded the RKE module program enable wire by sounding a single chime tone. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition off. DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in Programming Mode" does not appear, exit and select "Program RKE" again. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, press "Back Page". RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2397 Body Control Module: Description and Operation Part 3 of 3 VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE COMMUNICATIONS. Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system Will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2398 System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all door are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Test - NOTE: System self-test can be entered only with the DRB. NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. WIPER SYSTEM Front The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned OFF the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. DRB III (R) ERROR MESSAGES Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User- Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2399 DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition WARNINGS Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light GLOSSARY OF ACRONYMS ACM Airbag Control Module AECM Airbag Electronic Control Module (type of ACM) ASDM Airbag System Diagnostic Module (type of ACM) BCM body control module CAB controller antilock brake CCD Chrysler Collision Detection (vehicle communications bus) CMTC Compass/Mini-Trip Computer (module) DLC data link connector (previously called "engine diagnostic connector") DR driver HVAC heater, ventilation, air condition MET metric MIC mechanical instrument cluster MUX multiplexed ODO odometer PASS passenger PCM powertrain control module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2400 PDC powertrain distribution center PTC positive temperature coefficient RKE remote keyless entry TCM transmission control module VF vacuum fluorescent display VTSS vehicle theft security system Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures AM/FM Switch Inoperative SYMPTOM * AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Joystick Inoperative SYMPTOM * BALANCE JOYSTICK INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Cassette Error SYMPTOM CASSETTE ERROR POSSIBLE CAUSES - Cassette Error / Replace radio CD Eject Switch Inoperative SYMPTOM * CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Error SYMPTOM CD ERROR POSSIBLE CAUSES - Defective radio Equalizer Inoperative SYMPTOM * EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - Radio/CD cable loose/disconnected - DIN cable data bus (CAV 1) open - DIN cable data bus (CAV 3) open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2403 - DIN cable terminals shorted - DIN signal wires (CAVS 2, 4, and 5) open - DIN fused B(+) circuit open - DIN fused ignition switch output circuit open - DIN ground circuit open - DIN metal connectors open - Radio defective - Radio input control defective FF/RW Switch Inoperative SYMPTOM * FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM * HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12V output circuit defective, open - Radio ground circuit defective, open - Power relay output circuit defective, open - Radio 12V output circuit shorted to ground - Radio choke defective - Speaker power relay defective, open - Speaker power relay defective, open - Junction block defective, open circuit - Defective radio - Radio choke output circuit defective, open - Radio output circuits defective No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Door or quarter speaker (+) circuit defective, open - Door or quarter speaker (-) circuit defective, open - Door or quarter speaker (+) circuit open - Door or quarter speaker (-) circuit open - Instrument panel or pillar speaker (+) circuit open - Instrument panel or pillar speaker (-) circuit open - Door or quarter speaker defective - Speaker defective, no response Pause/Play Switch Inoperative SYMPTOM * PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2404 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector defective - Antenna connections defective - Hood ground defective - Ground circuit defective, open - Radio connectors not properly connected - Ignition / alternator system noise - Radio defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Ground circuit open - Instrument panel - pillar speaker defective - Radio choke output circuit open - Speaker (+) and (-) circuits shorted together - Inoperative speaker defective PWR Switch Inoperative SYMPTOM * PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Radio Error SYMPTOM RADIO ERROR POSSIBLE CAUSES - Defective radio Remote Controls Inoperative SYMPTOM * REMOTE CONTROLS INOPERATIVE POSSIBLE CAUSES - No response, CCD bus failure - Radio control harness defective, open - Radio control MUX circuit shorted - Remote control switch defective - MUX control clockspring defective - Radio control ground circuit to BCM open - Radio control MUX circuit open - Radio MUX control circuit defective - Body Control Module defective Scan Switch Inoperative SYMPTOM * SCAN SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2405 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM * SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Set Switch Inoperative SYMPTOM * SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Left door speaker shorted - Left front instrument panel speaker shorted - Right door speaker shorted - Right front instrument panel speaker shorted - Right front (-) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (+) circuit shorted to ground - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left door speaker defective, shorted - Left front instrument panel speaker defective, shorted - Left quarter speaker shorted - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear speaker shorted - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Right rear quarter speaker shorted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2406 - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear quarter speaker shorted - Left rear speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Right rear pillar speaker shorted - Radio output circuits defective Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right channel speaker shorted - Right instrument panel speaker defective, shorted - Right front (+) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (-) circuit shorted to ground - Right pillar speaker shorted - Right quarter speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Radio output circuits defective Tape Eject Switch Inoperative SYMPTOM * TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Tune Switch Inoperative SYMPTOM * TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM * VOL/TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM * 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2407 Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - BCM fails chime test Chime Inoperative With Driver Seat Belt Unfastened SYMPTOM * CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Ground circuit to left seat belt switch connector open - Left seat belt switch open - BCM not responding to belt switch - Body Control Module seat belt switch sense open - Seat belt switch sense circuit open Chime Inoperative With Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition Switch - key in switch shorted - BCM - no chime response - head/park lamps ON - BCM - key in sense shorted default - BCM - no response to park lamp switch - Chime inoperative with exterior lamps ON Chime Inoperative With Key In Ignition & Driver Door Open SYMPTOM * CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Ignition switch ground circuit open - Key in ignition switch sense circuit open - Ignition switch - key in switch open - BCM - no chime to key in ignition - BCM not responding to key in switch Chime Inoperative With L or R Turn Signal On For 1 Mile SYMPTOM * CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE POSSIBLE CAUSES - Junction block - Left turn signal open - Junction block - Right turn signal open - BCM - no response to turn signal - BCM fails speed test - Chime - speedometer problem - Chime inoperative - turn signal on for 1 mile Chime Inoperative With Low Oil Pressure SYMPTOM Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2408 * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With the Dome Lamps On SYMPTOM * CHIME INOPERATIVE WITH THE DOME LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM failed - door open & key out default - BCM - key in switch sense shorted default Chime Sounds With Driver Door Open & Key Out SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM - key in switch sense shorted default - BCM not responding to key out Chime Sounds With Driver Seat Belt Fastened SYMPTOM * CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch sense circuit shorted to ground - Left seat belt switch shorted - BCM - no response to seat belt fastened - BCM seat belt switch input shorted to ground Auto Headlamps Will Not Turn Off SYMPTOM * AUTO HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - No response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Auto headlamp signal circuit shorted to ground - Electrochromic mirror defective - sensor stuck ON (default) - BCM defective - auto headlamp sensor stuck ON Auto Headlamps Will Not Turn On SYMPTOM * AUTO HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - NO response (BCM) - CCD bus failure - NO response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Electrochromic mirror defective (default) - BCM defective - auto headlamp sensor Fog Lamps Will Not Turn Off SYMPTOM * FOG LAMPS WILL NOT TURN OFF Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2409 POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp switched ground circuit shorted to ground - Headlamp switch defective - foglamp switched ground Fog Lamps Will Not Turn On SYMPTOM * FOG LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp bulbs open - Fog lamp relay control circuit open - Fog lamp relay output circuit open - Fog lamp relay defective, open - Multifunction dimmer switch defective (open) default - Fog lamp switched ground circuit open - BCM defective - Headlamp relay control - Multifunction switch defective (fog lamp relay control) default - Headlamp relay control circuit (foglamps) open Headlamps Will Not Turn Off SYMPTOM * HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch sense circuit shorted to ground - Headlamp relay control circuit shorted to ground - Low beam relay control circuit shorted to ground - Low beam relay control circuit (QUAD) shorted to ground - Low beam headlamp relay (QUAD) defective, shorted - Low beam headlamp relay defective (shorted) by default - PDC defective (low beam headlamp relay connector shorted) - Headlamp switch defective - switch sense - BCM defective (headlamp switch sense function) by default - BCM defective (low beam relay control shorted) by default Headlamps Will Not Turn On SYMPTOM * HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Both low beam fuses open - Fused low beam output circuit open (both lamps inoperative) - Fused low beam output circuit open (one lamp inoperative) - Headlamp defective (by default) - Headlamp fuse open - Headlamp switch sense circuit open - Headlamps defective (by default) - Multifunction switch defective (default) - Headlamp relay control circuit open - Low beam relay control circuit (Chrysler) open - Low beam relay control circuit open - Low beam headlamp relay defective (by default) - Low beam relay defective - relay control function - PDC defective - B(+) circuit at low beam fuse terminal - Power Distribution Center defective (low beam relay CAV A) - Power Distribution Center defective (low beam relay CAV B) - Headlamp switch defective (by default) - BCM defective - headlamp switch sense function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2410 - BCM defective - headlamp switch sense stuck open - BCM defective - low beam relay control open Park Lamps Will Not Turn Off SYMPTOM * PARK LAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Park lamp relay control circuit shorted to ground - Park lamp relay output circuit shorted to voltage - Park lamp switch sense circuit shorted to ground - Park lamp relay defective - control shorted (by default) - Headlamp switch defective - shorted - BCM defective - park lamp switch sense closed (by default) Park Lamps Will Not Turn On SYMPTOM * PARK LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Fused park lamp output circuit open - Park lamp bulb defective (by default) - Park lamp fuse in PDC open - Both park lamp fuses open - Park lamp fuse open - Park lamp relay control circuit open - Park lamp relay output circuit open - Park lamp switch sense circuit open - Park lamp relay defective (control function) - PDC defective - other B(+) cavity - PDC defective - park lamp relay connector, fused B(+) - Headlamp switch defective - park lamps (by default) - BCM defective - park lamp switch sense stuck open - BCM defective - park lamp switch sense function - BCM defective - parklamp control function (by default) ABS Warning Lamp SYMPTOM * ABS WARNING LAMP POSSIBLE CAUSES - BCM connector observable defect - CAB connector observable defect - Fused ignition switch output circuit open - ABS warning lamp defective - ABS warning lamp driver circuit open - ABS warning lamp driver circuit shorted to ground - ABS warning lamp flashing - BCM defective - CAB defective Airbag Warning Lamp SYMPTOM * AIRBAG WARNING LAMP POSSIBLE CAUSES - Airbag warning lamp failure All Warning Lamps Out SYMPTOM * ALL WARNING LAMPS OUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2411 POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Information Center defective Engine Temperature Warning Lamp SYMPTOM * ENGINE TEMPERATURE WARNING LAMP POSSIBLE CAUSES - Engine temperature lamp staying on - Temperature lamp not working - Engine temperature lamp/bulb defective - Fused ignition switch output circuit open - Defective BCM - Engine temperature warning lamp driver circuit open - Temperature warning lamp driver circuit shorted to ground - Information Center defective - Body Control Module defect - Defective Information Center High Beam Indicator Lamp SYMPTOM * HIGH BEAM INDICATOR LAMP POSSIBLE CAUSES - Headlamps inoperative - Fused right highbeam output circuit open - Ground circuit open - High beam indicator bulb defective - Defective Information Center Low Oil Pressure Warning Lamp SYMPTOM * LOW OIL PRESSURE WARNING LAMP POSSIBLE CAUSES - Oil pressure low - Oil warning lamp/bulb defective - Oil level low - Defective oil pressure switch - Oil pressure switch sense circuit shorted to ground - Oil pressure switch sense circuit open - Oil pressure switch defective - BCM defective - Defective Information Center Red Brake Warning Lamp SYMPTOM * RED BRAKE WARNING LAMP POSSIBLE CAUSES - Park brake pedal problem - Vehicle equipped antilock brakes - Brake fluid level low - Red brake warn lamp/bulb defective - Ground circuit open - Brake fluid level switch defective - Defective ignition switch - Defective park brake switch - Red brake warning lamp circuit open - Red brake warning lamp circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2412 - Information Center faulty - Ignition switch defective - Red brake warning lamp driver circuit open - Red brake warning lamp driver circuit faulty Service Engine Soon Lamp SYMPTOM * SERVICE ENGINE SOON LAMP POSSIBLE CAUSES - DTC's are present - Bulb & socket defective - Service Engine Soon indicator lamp driver circuit open - Service Engine Soon indicator lamp circuit shorted to ground - Defective Information Center circuit board - Powertrain Control Module defective Turn Signal Indicator Lamp SYMPTOM * TURN SIGNAL INDICATOR LAMP POSSIBLE CAUSES - Turn signal lamps inoperative - Ground circuit open - Left turn signal circuit open - Right turn signal circuit open - Turn signal bulbs defective - Junction Block defective - BCM defective - Information Center defective Vehicle Theft Alarm Indicator SYMPTOM * VEHICLE THEFT ALARM INDICATOR POSSIBLE CAUSES - Vehicle theft alarm indicator defective All Gauges Inoperative SYMPTOM * ALL GAUGES NOT OPERATING POSSIBLE CAUSES - BCM instrument cluster circuit output defective - Instrument Cluster PC board defective - DRB shows ignition unlock closed - No response - CCD bus instrument cluster - Body computer odometer failure - RAM test failure - ROM test failure Cluster Illumination SYMPTOM * CLUSTER ILLUMINATION POSSIBLE CAUSES - No response - CCD bus instrument cluster - Headlamp switch ground circuit defective - Inoperative lamp defective - Headlamp switch defective - Junction block defective - Dimmer switch signal circuit open - Dimmer switch signal circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2413 - Instrument panel lamps driver circuit shorted to ground - Panel lamps driver circuit open - Park lamps not lighting - Instrument Cluster circuit board defective - BCM dimmer switch signal circuit output faulty - BCM defective - BCM defective by default - Body computer odometer failure - BCM dimmer switch signal circuit defective - Illumination panel fuse OK - Inoperative lamp ground circuit - RAM test failure - ROM test failure Cluster Warning Lamps Odometer and PRNDL Display SYMPTOM * CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY POSSIBLE CAUSES - Any one lamp/bulb defective - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Body computer odometer failure DTC - No response - CCD bus instrument cluster - Washer fluid level switch defective - BCM washer fluid switch sense circuit input defective - All segments fail to light - Faulty odometer and PRNDL lamp - Generator lamp failure - Instrument cluster printed circuit board defective Gauges Not Returning to Zero With Key Off SYMPTOM * GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF POSSIBLE CAUSES - Fused B(+) circuit open - No response - CCD bus instrument cluster - Instrument Cluster PC board defective - Body computer odometer failure - RAM test failure - ROM test failure One Gauge Not Operating Properly SYMPTOM * ONE GAUGE OPERATING IMPROPERLY POSSIBLE CAUSES - DRB reads active on the bus - DRB reads no vehicle speed sense signal code - IOD fuse is loose in junction block - Speedometer calibration out - Any one lamp/bulb defective - DRB reading not matching RPM - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Washer fluid level switch defective - Gauge pack defective - Speedometer/Odometer gauge pack defective - Tachometer calibration out - Cooling system condition faulty - DRB reads coolant temperature sensor code Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2414 - DRB reads engine temperature accurately - BCM instrument cluster circuit output defective - Body Control Module defective - Gauge pack defective - Instrument Cluster printed circuit board defective - DRB shows ignition unlock closed - BCM washer fluid level switch sense circuit input defective - All segments fail to light - BCM temperature gauge input defective - Faulty odometer and PRNDL lamp - Generator lamp failure - PCM defective - Pinion factor failure Trip and Rest Button(S) SYMPTOM * TRIP AND RESET BUTTON(S) POSSIBLE CAUSES - Trip & reset button(s) defective Courtesy Lamps Inoperative W/Dome Lamp Switch SYMPTOM * COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH POSSIBLE CAUSES - Courtesy lamp switch sense circuit open - Headlamp switch defective - courtesy lamp function open - BCM defective - courtesy lamp switch sense (by default) - BCM defective - dome lamp switch function Courtesy Lamps Inoperative With Any Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH ANY DOOR POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay control circuit open - Switched courtesy lamp relay control circuit open - Junction block defective - lamp relay fused B(+) (CAV 87) open - Courtesy lamp relay defective - coil open - Junction block defective - lamp relay fused B(+) (CAV 30) open - Junction block defective - lamp relay fused B(+) (CAV 86) Open - Headlamp switch defective - open - BCM defective - lamp relay control function (by default) - BCM defective - driver door ajar switch status Courtesy Lamps Inoperative With Driver Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR POSSIBLE CAUSES - Driver door ajar switch defective, open - Driver door ajar switch sense circuit open - Left front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Left Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR POSSIBLE CAUSES - Left sliding door ajar switch sense circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2415 - Left sliding door ajar ground circuit open - Left sliding door ajar switch defective, open - BCM defective Courtesy Lamps Inoperative With Liftgate SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LIFTGATE POSSIBLE CAUSES - Liftgate ground circuit open - Liftgate ajar switch open - ajar switch disconnected - Liftgate ajar switch sense circuit open - BCM defective, open Courtesy Lamps Inoperative With Passenger Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR POSSIBLE CAUSES - Passenger door ajar switch defective, open - Passenger door ajar switch sense circuit open - Right front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Right Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR POSSIBLE CAUSES - Right sliding door ajar switch defective, open - Right sliding door ajar switch sense circuit open - Right sliding door ajar ground circuit open - BCM defective, open Courtesy Lamps On at All Times SYMPTOM * COURTESY LAMPS ON AT ALL TIME POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay output circuit shorted to B(+) - Courtesy lamp relay control circuit shorted to ground - Switched courtesy lamp relay control circuit shorted to ground - Courtesy lamp relay defective - coil shorted - Headlamp switch shorted - BCM defective - relay control shorted (by default) Illuminated Entry Inoperative With Driver Door Key Cylinder SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER POSSIBLE CAUSES - Driver door key switch unlock position stuck - Driver door key cylinder switch defective - Driver door key switch sticking Illuminated Entry Inoperative With RKE Transmitter SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2416 - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective unlock switch - RKE module default replacement - RKE module defective CMTC Avg MPH/Fuel Economy Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR WRONG POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative CMTC Elapsed Time Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective BCM / Indicator lights CMTC Fails to Respond to Instrument Cluster Dimming SYMPTOM * COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Trip Odometer Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE/WRONG. POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative Compass/Mini-Trip Computer Displaying OC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING OC POSSIBLE CAUSES - Open sensor ground circuit - Ambient Temperature Sensor defective - Open Ambient Temperature Sensor signal circuit - Defective Compass/Mini-Trip Module - sensor ground circuit. Compass/Mini-Trip Computer Displaying SC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING SC POSSIBLE CAUSES - Defective Ambient Temperature Sensor - Ambient Temperature Sensor signal circuit shorted to ground - Compass/Mini-Trip Module default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2417 Compass/Mini-Trip Computer Segments Fail to Light SYMPTOM * COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - segments fail to light Compass/Mini-Trip Computer Shows Failed SYMPTOM * COMPASS/MINI-TRIP COMPUTER SHOWS FAILED POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - shows failed Compass/Mini-Trip Computer Switch Inoperative SYMPTOM * COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Incorrect Ambient Temperature Readings SYMPTOM * INCORRECT AMBIENT TEMPERATURE READINGS POSSIBLE CAUSES - Open sensor ground - defective CMTM - Sensor ground circuit partial short to ground - Defective Ambient Temperature Sensor/Road test - Ambient Temperature Sensor signal circuit partial short - Ambient Temperature Sensor signal circuit shorted - Defective Compass/Mini-Trip Module - Defective Compass/Mini-Trip Module sensor ground circuit Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH POSSIBLE CAUSES - Junction block defective - Door unlock relay output circuit open - Door unlock relay output circuit resistance low Additional All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door unlock relay control inoperative at BCM - Door unlock relay defective - Door unlock relay coil resistance out of tolerance - Door unlock relay output circuit shorted to ground Additional All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2418 POSSIBLE CAUSES - Passenger door switch MUX shorted to battery - Door lock switch resistance high in unlock position - Driver door switch MUX circuit shorted to battery - Liftgate switch MUX shorted to battery - BCM door lock relay control circuit inoperative - Liftgate switch MUX at BCM defective - Door lock relay control ground circuit open - Door lock relay defective - Fuse # 26 defective - Fused B(+) circuit open - Fused B(+) circuit shorted to ground - Ground circuit open at door lock relay connector Additional All Doors Fail to Lock and Unlock From One Switch SYMPTOM ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH POSSIBLE CAUSES - Door key cylinder switch connector circuit ground circuit open - Door key cylinder switch defective - Liftgate key cylinder switch defective - Liftgate switch MUX shorted to battery - Door switch MUX circuit to BCM open - Driver door switch MUX circuit open at BCM connector - Liftgate switch MUX circuit open at BCM connector - Liftgate switch MUX circuit to BCM open - Passenger door switch MUX circuit open at BCM connector - Passenger door switch MUX circuit to BCM open - Door lock switch connector ground circuit open - Door lock switch defective - Door lock switch MUX circuit open - Door locks inoperative from key cylinder switch - Door switch MUX circuit shorted to battery Additional All Doors Failing to Lock From Any Switch SYMPTOM ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door lock relay control circuit from BCM fails - Key - in ignition switch circuit to BCM defective - Door lock relay does not operate - Door lock relay coil resistance out of tolerance - Door lock relay output shorted to ground - Ignition switch defective - Key - in ignition switch sense circuit shorted to ground Additional Driver Door (w/RKE) Failing to Unlock From Any SW SYMPTOM ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Driver door unlock relay coil resistance out of tolerance - Driver door unlock relay defective - Driver door unlock relay output circuit shorted to ground - Voltage too low at junction block fused B(+) circuit Additional One Door Fails to Lock and Unlock From Any Switch SYMPTOM ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2419 POSSIBLE CAUSES - RKE equipped door lock fails to lock & unlock - Door lock motor defective - Driver unlock relay ground open in junction block - Door lock relay output circuit open - Door unlock relay output circuit open - Driver door unlock relay open All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective door unlock switch - RKE module default replacement - RKE module defective All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Defective door lock switch - Defective unlock switch All Doors Fail to Lock and Unlock From One Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Lock From Any Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2420 - Defective unlock switch All Doors Failing to Lock From One Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Unlock From One Switch SYMPTOM * ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Automatic Door Locks Do Not Lock Over 15 MPH SYMPTOM * AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH POSSIBLE CAUSES - Link to body communication bus inoperative - TPS malfunction causes door lock problem - VSS malfunction causes door lock problem - Auto door lock not enabled Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - BCM defective - BCM sends wrong key - in ignition status - BCM a connector terminals damaged - Ignition switch open - Key - in ignition switch ground circuit open - Key - in ignition switch sense circuit open Driver Door (w/RKE) Failing to Unlock From Any Switch SYMPTOM * DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch One Door Fails to Lock and Unlock From Any Switch SYMPTOM * ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2421 This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Remote Keyless Entry Problem SYMPTOM * RKE PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - RKE module default replacement - RKE module defective Front Wiper Operating Constantly W/Switch In Off Position SYMPTOM * FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION POSSIBLE CAUSES - Front wiper ON/OFF relay control circuit shorted to ground - Defective wiper ON relay/substitute relay - Defective multifunction switch/voltage - High/Low wiper relay HI speed output circuit shorted to voltage - High/Low wiper relay LO speed output circuit shorted to voltage - Defective BCM - 100 ohms default Front Wipers Not Parking In Off Position SYMPTOM * FRONT WIPERS NOT PARKING IN OFF POSITION TEST NOTE This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN POSSIBLE CAUSES - Wiper park switch toggle closed/open - Open wiper park switch sense circuit - Defective BCM - wiper park switch - Defective wiper motor/wiper park switch Front Wipers Not Working at All SYMPTOM * FRONT WIPERS NOT WORKING AT ALL POSSIBLE CAUSES - Open wiper on relay control circuit - BCM/wiper relay - Defective wiper ON relay - BCM/ground - Front wiper switch MUX circuit shorted to ground - Open front wiper switch MUX circuit between switch and BCM - Defective High/Low wiper relay - relay connector - Defective multifunction switch/front wiper switch - High/Low wiper relay HI speed output circuit shorted to ground - High/Low wiper relay LO speed output circuit shorted to ground - Open ground circuit/lights - Open High/Low relay LO speed output circuit between High/Low relay and wiper motor - Open fused ignition switch output circuit/multifunction switch - Defective Power Distribution Center - relay connector Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2422 - Defective Power Distribution Center - front wiper relay - Defective Power Distribution Center - wiper ON relay - Defective Power Distribution Center - wiper relay - Defective Power Distribution Center - H/L relay - Defective Power Distribution Center - B(+) circuit. - Defective wiper motor/harness - Defective BCM/wiper relay - Defective BCM/front wiper MUX - Defective BCM/sensors - Defective wiper motor ground circuit. Front Wipers Not Working In High Speed Mode SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE POSSIBLE CAUSES - Open HI/LO wiper relay control circuit - Defective HI/LO wiper RELAY - Wiper switch - Open wiper HI/LO relay HI speed output circuit - Defective multi - FUNCT switch/ ground circuit - Defective power DIST CNTR-H/L WPR RLY - Defective wiper Motor/HI speed output circuit - Open ground circuit/Multi - Function switch Front Wipers Not Working In Intermittent Mode SYMPTOM * FRONT WIPERS NOT WORKING IN INTERMITTENT MODE POSSIBLE CAUSES - Defective multifunction switch/positions - Defective BCM/wiper positions - Defective multifunction switch/Default Front Wipers Not Working In Low Speed Mode SYMPTOM * FRONT WIPERS NOT WORKING IN LOW SPEED MODE POSSIBLE CAUSES - High/Low wiper relay control circuit shorted to ground - Defective High/Low wiper relay - fused ignition switch - Open High/Low wiper relay - LO speed output circuit - Defective wiper motor/LO speed output circuit Rear Washer Motor Inoperative SYMPTOM * REAR WASHER MOTOR INOPERATIVE POSSIBLE CAUSES - Open rear washer motor control circuit - Defective rear washer motor/jumper - Open fused ignition switch output circuit/voltage - Defective HVAC Control Module / 3.8 volts - Defective BCM - washer motor operate Rear Wiper Not Parking In the Off Position SYMPTOM * REAR WIPER NOT PARKING IN THE OFF POSITION POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective HVAC Control Module/switch indicator lights - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2423 - Defective BCM/washer motor run - Defective BCM/cycle on default - Defective BCM/rear wiper switch voltage - Defective rear wiper motor/test light Rear Wiper Not Working at All SYMPTOM * REAR WIPER NOT WORKING AT ALL POSSIBLE CAUSES - Open rear wiper motor control circuit - Open rear wiper switch MUX circuit - Open ground circuit/rear wiper motor - Open fused ignition switch output circuit/fuse # 6 - Open fused ignition switch output circuit/fuse # 8 - Shorted fused ignition switch output circuit/fuse # 6 - Defective rear wiper motor/motor control - Defective HVAC Control Module/default - Defective HVAC Control Module/rear wiper switch MUX - Defective BCM/rear wiper switch MUX - Defective BCM/rear wiper motor - Defective HVAC Control Module/21-Way connector Rear Wiper Not Working In the Intermittent Mode SYMPTOM * REAR WIPER NOT WORKING IN THE INTERMITTENT MODE POSSIBLE CAUSES - Defective rear wiper motor/intermittent switch - Defective HVAC Control Module/indicator light - Defective HVAC Control Module/rear wiper switch - Defective BCM/test light default Rear Wiper/Wash Working Continuously SYMPTOM * REAR WIPER/WASH WORKING CONTINUOUSLY POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default - Defective BCM/washer motor run - Defective BCM/rear wiper switch voltage Wiper/Wash Function Not Working Properly SYMPTOM * WIPER/WASH FUNCTION NOT WORKING PROPERLY POSSIBLE CAUSES - Defective washer motor/washer pump control - Operate wipers - Open washer pump control circuit - Defective multifunction switch/washer pump control - Open fused ignition switch output circuit - Defective junction block/BCM - Defective junction block/block connector - Defective BCM/junction block - Defective BCM/stalk switch - Fused ignition switch output circuit shorted to ground - Open washer pump control circuit/multifunction switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2424 Body Control Module: Component Tests and General Diagnostics Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2425 Body Control Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2426 Body Control Module: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) Body Control Module - Location 4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Refer to Instrument Panel and Systems, Body Control Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2427 Body Control Module: Tools and Equipment DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2431 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2432 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2433 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2434 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2435 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2436 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2437 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Temperature Sensor 7 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2441 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2442 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2443 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2444 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40° F to 265° F). The engine coolant temperature sensor provides an input voltage to the PCM. As coolant temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle speeds until normal operating temperatures are reached. The engine coolant sensor is also used for cooling fan control. Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2445 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant Temperature Sensor 1. With the key off, disconnect wire harness connector from coolant temperature sensor. Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter should read as follows: a. ECT STET at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2446 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2450 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2451 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2452 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2453 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2454 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2455 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2461 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2462 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2463 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2464 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2465 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2466 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2467 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2468 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2469 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2470 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2471 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2472 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 Data Link Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2480 Data Link Connector: Description and Operation Data Link Connector DATA LINK CONNECTOR-PCM OUTPUT The data link connector provides the technician with the means to connect the DRB scan tool to diagnosis the vehicle. The connector is located under the dash. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation ELECTRONIC EGR TRANSDUCER SOLENOID-PCM OUTPUT EGR Solenoid EGR Solenoid EGR Solenoid The electronic EGR transducer contains an electrically operated solenoid and a back-pressure transducer. The PCM operates the solenoid. The PCM determines when to energize the solenoid. Exhaust system back-pressure controls the transducer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation > Page 2484 When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to the transducer when the PCM de-energizes the solenoid. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Power Distribution Center & Powertrain Control Module (PCM) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Powertrain Control Module C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2510 Powertrain Control Module: Description and Operation OPERATION Powertrain Control Module The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet changing engine operating conditions. During the crank-start period the PCM advances ignition timing a set amount. During engine operation, the amount of spark advance provided by the PCM is determined by the following input factors: available manifold vacuum - barometric pressure - engine coolant temperature - engine RPM - throttle position The PCM also regulates the fuel injection system. Refer to the Fuel Injection. The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2511 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection Power Distribution Center Retaining Screws 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket. Battery Heat Shield 3. Remove heat shield from battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2512 Battery Clamp 4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle. PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2513 PCM 40-way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both way connectors. PCM Removal/Installation 9. Remove 3 screws holding PCM to fender. 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The level sensor is attached to the side of the fuel pump module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2517 Fuel Level Sensor: Description and Operation DESCRIPTION The level sensor is attached to the side of the fuel pump module. The level sensor consists of a float, an arm, and a variable resistor. OPERATION As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2518 Fuel Level Sensor: Testing and Inspection This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Level Sensor Diagnosis The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2519 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector. NOTE: The pump module harness on TOP of flange is not serviceable or removable. Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2520 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Level Sensor Removal/Installation 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2521 Groove In Back Side Of Level Sensor 2. Wrap wires into groove in back of level sensor. Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Motor Screws 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2525 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2526 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2527 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL MOTOR-PCM OUTPUT The idle air control motor is mounted on the throttle body. The PCM operates the idle air control motor. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load or ambient conditions. The throttle body has an air bypass passage that provides air for the engine at idle (the throttle blade is closed). The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the idle air control motor pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, and various switch operations (brake, park/neutral, air conditioning). Deceleration die out is also prevented by increasing airflow when the throttle is closed quickly after a driving (speed) condition. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2528 Idle Speed/Throttle Actuator - Electronic: Service and Repair When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from idle air control motor. Servicing Idle Air Control Motor 3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the O-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new O-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 2 Nm (17 in. lbs.) torque. 4. Connect electrical connector to idle air control motor. 5. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2534 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2535 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2536 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2537 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2538 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2539 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2540 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Information Bus: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 Vehicle Communication Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2552 Information Bus: Description and Operation VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system called "bus + " (bus plus) and "bus - " (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus (+) and bus (-) at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE COMMUNICATIONS. Any of the following bus failure messages may be displayed. Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2556 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2557 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2558 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2559 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2563 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2585 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2586 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2589 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 2590 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR (CHECK ENGINE) LAMP-PCM OUTPUT The PCM supplies the malfunction indicator (check engine) lamp on/off signal to the instrument panel through the CCD Bus. The CCD Bus is a communications port. Various modules use the CCD Bus to exchange information. The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3 seconds as a bulb test. The Malfunction Indicator Lamp (MIL) stays on continuously, when the PCM has entered a Limp-In mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM compensates for the failure of certain components that send incorrect signals. The PCM substitutes for the incorrect signals with inputs from other sensors. If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the MIL. At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger the MIL (Check Engine Lamp) refer to the On-Board Diagnostics Chart. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Sensor Tightening Torque 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2597 MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2598 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2599 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. MAP Sensor MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2600 MAP Sensor The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The sensor connects electrically to the PCM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2601 Manifold Pressure/Vacuum Sensor: Testing and Inspection To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. MAP Sensor Connector 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3. With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (± 0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If not OK, repair or replace the wire harness as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2602 Manifold Pressure/Vacuum Sensor: Service and Repair Map Absolute Pressure Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the intake manifold. INSTALLATION 1. Reverse the above procedure for installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Oxygen Sensor 27 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2608 Oxygen Sensor: Locations Oxygen Sensor(s) Heated Oxygen Sensor Downstream Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2609 Oxygen Sensor: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2610 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2611 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2612 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR Heated Oxygen Sensor Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2613 Heated Oxygen Sensor The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2614 Oxygen Sensor: Testing and Inspection Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical connector from each oxygen sensor. The white wires in the sensor connector are the power and ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement REMOVAL 1. Raise and support vehicle. WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. Oxygen Sensor Grommet Cover 2. Remove grommet cover to expose connector. Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector. Oxygen Sensor Removal/Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2617 INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2618 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Upstream Heated Oxygen Sensor The oxygen sensor is installed in the exhaust manifold . CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions NUMBER: 26-12-99G GROUP: Miscellaneous DATE: December, 1999 THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the wiring schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2624 8W-44-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2625 8W-44-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2626 8W-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2627 8W-50-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2628 8W-50-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2629 8W-50-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2630 8W-80-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2631 8W-90-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2632 8W-90-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2633 Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2634 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2635 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2636 Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set NO: 18-25-98 GROUP: Vehicle Performance DATE: Aug. 14, 1998 SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code MODELS: 1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE. DISCUSSION: During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous "EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the ignition to the ON position and determine if each PRNDL indicator in the instrument cluster becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not necessary to replace the BCM. NOTE: CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL FAILURE IN THE PRNDL SYSTEM. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2637 Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2640 Junction Block, Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Body Control Module: Connector Views Body Control Module C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 Body Control Module C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Body Control Module Interconnect Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Body Control Module: Electrical Diagrams BCM Block Diagram Wiring Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 Body Control Module -- Sheet 8w-45-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 Body Control Module -- Sheet 8w-45-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Body Control Module -- Sheet 8w-45-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 Body Control Module -- Sheet 8w-45-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 Body Control Module -- Sheet 8w-45-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 Body Control Module -- Sheet 8w-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 Body Control Module -- Sheet 8w-45-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 Body Control Module -- Sheet 8w-45-9 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 2674 Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 Body Control Module: Description and Operation Part 1 of 3 INTRODUCTION Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. This information will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not come on at all - warning lamp stays on BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: automatic door locks - battery protection - CCD radio - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2677 - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar, ignition, RKE actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as described above. Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and glove box closed). Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened, The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2678 Body Control Module: Description and Operation Part 2 of 3 COMPASS/MINI-TRIP COMPUTER The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. See the service procedure. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Compass Magnetic Variance Zones Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the following zone map provided. The number shown for your area is the variance number for your area. 1. Set the compass/mini-trip console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation, NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS. MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb check is performed. This consists of activating all CCD controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2679 as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Programming an RKE Transmitter Customer Programming Method NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED. 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds. While still holding the unlock button, press the panic button, then release both buttons. The BCM will acknowledge that it has grounded the RKE module program enable wire by sounding a single chime tone. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition off. DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in Programming Mode" does not appear, exit and select "Program RKE" again. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, press "Back Page". RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2680 Body Control Module: Description and Operation Part 3 of 3 VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE COMMUNICATIONS. Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system Will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2681 System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all door are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Test - NOTE: System self-test can be entered only with the DRB. NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. WIPER SYSTEM Front The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned OFF the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. DRB III (R) ERROR MESSAGES Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User- Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2682 DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition WARNINGS Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light GLOSSARY OF ACRONYMS ACM Airbag Control Module AECM Airbag Electronic Control Module (type of ACM) ASDM Airbag System Diagnostic Module (type of ACM) BCM body control module CAB controller antilock brake CCD Chrysler Collision Detection (vehicle communications bus) CMTC Compass/Mini-Trip Computer (module) DLC data link connector (previously called "engine diagnostic connector") DR driver HVAC heater, ventilation, air condition MET metric MIC mechanical instrument cluster MUX multiplexed ODO odometer PASS passenger PCM powertrain control module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 2683 PDC powertrain distribution center PTC positive temperature coefficient RKE remote keyless entry TCM transmission control module VF vacuum fluorescent display VTSS vehicle theft security system Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures AM/FM Switch Inoperative SYMPTOM * AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Joystick Inoperative SYMPTOM * BALANCE JOYSTICK INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Cassette Error SYMPTOM CASSETTE ERROR POSSIBLE CAUSES - Cassette Error / Replace radio CD Eject Switch Inoperative SYMPTOM * CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Error SYMPTOM CD ERROR POSSIBLE CAUSES - Defective radio Equalizer Inoperative SYMPTOM * EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - Radio/CD cable loose/disconnected - DIN cable data bus (CAV 1) open - DIN cable data bus (CAV 3) open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2686 - DIN cable terminals shorted - DIN signal wires (CAVS 2, 4, and 5) open - DIN fused B(+) circuit open - DIN fused ignition switch output circuit open - DIN ground circuit open - DIN metal connectors open - Radio defective - Radio input control defective FF/RW Switch Inoperative SYMPTOM * FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM * HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12V output circuit defective, open - Radio ground circuit defective, open - Power relay output circuit defective, open - Radio 12V output circuit shorted to ground - Radio choke defective - Speaker power relay defective, open - Speaker power relay defective, open - Junction block defective, open circuit - Defective radio - Radio choke output circuit defective, open - Radio output circuits defective No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Door or quarter speaker (+) circuit defective, open - Door or quarter speaker (-) circuit defective, open - Door or quarter speaker (+) circuit open - Door or quarter speaker (-) circuit open - Instrument panel or pillar speaker (+) circuit open - Instrument panel or pillar speaker (-) circuit open - Door or quarter speaker defective - Speaker defective, no response Pause/Play Switch Inoperative SYMPTOM * PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2687 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector defective - Antenna connections defective - Hood ground defective - Ground circuit defective, open - Radio connectors not properly connected - Ignition / alternator system noise - Radio defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Ground circuit open - Instrument panel - pillar speaker defective - Radio choke output circuit open - Speaker (+) and (-) circuits shorted together - Inoperative speaker defective PWR Switch Inoperative SYMPTOM * PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Radio Error SYMPTOM RADIO ERROR POSSIBLE CAUSES - Defective radio Remote Controls Inoperative SYMPTOM * REMOTE CONTROLS INOPERATIVE POSSIBLE CAUSES - No response, CCD bus failure - Radio control harness defective, open - Radio control MUX circuit shorted - Remote control switch defective - MUX control clockspring defective - Radio control ground circuit to BCM open - Radio control MUX circuit open - Radio MUX control circuit defective - Body Control Module defective Scan Switch Inoperative SYMPTOM * SCAN SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2688 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM * SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Set Switch Inoperative SYMPTOM * SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Left door speaker shorted - Left front instrument panel speaker shorted - Right door speaker shorted - Right front instrument panel speaker shorted - Right front (-) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (+) circuit shorted to ground - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left door speaker defective, shorted - Left front instrument panel speaker defective, shorted - Left quarter speaker shorted - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear speaker shorted - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Right rear quarter speaker shorted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2689 - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear quarter speaker shorted - Left rear speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Right rear pillar speaker shorted - Radio output circuits defective Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right channel speaker shorted - Right instrument panel speaker defective, shorted - Right front (+) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (-) circuit shorted to ground - Right pillar speaker shorted - Right quarter speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Radio output circuits defective Tape Eject Switch Inoperative SYMPTOM * TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Tune Switch Inoperative SYMPTOM * TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM * VOL/TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM * 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2690 Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - BCM fails chime test Chime Inoperative With Driver Seat Belt Unfastened SYMPTOM * CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Ground circuit to left seat belt switch connector open - Left seat belt switch open - BCM not responding to belt switch - Body Control Module seat belt switch sense open - Seat belt switch sense circuit open Chime Inoperative With Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition Switch - key in switch shorted - BCM - no chime response - head/park lamps ON - BCM - key in sense shorted default - BCM - no response to park lamp switch - Chime inoperative with exterior lamps ON Chime Inoperative With Key In Ignition & Driver Door Open SYMPTOM * CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Ignition switch ground circuit open - Key in ignition switch sense circuit open - Ignition switch - key in switch open - BCM - no chime to key in ignition - BCM not responding to key in switch Chime Inoperative With L or R Turn Signal On For 1 Mile SYMPTOM * CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE POSSIBLE CAUSES - Junction block - Left turn signal open - Junction block - Right turn signal open - BCM - no response to turn signal - BCM fails speed test - Chime - speedometer problem - Chime inoperative - turn signal on for 1 mile Chime Inoperative With Low Oil Pressure SYMPTOM Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2691 * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With the Dome Lamps On SYMPTOM * CHIME INOPERATIVE WITH THE DOME LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM failed - door open & key out default - BCM - key in switch sense shorted default Chime Sounds With Driver Door Open & Key Out SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM - key in switch sense shorted default - BCM not responding to key out Chime Sounds With Driver Seat Belt Fastened SYMPTOM * CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch sense circuit shorted to ground - Left seat belt switch shorted - BCM - no response to seat belt fastened - BCM seat belt switch input shorted to ground Auto Headlamps Will Not Turn Off SYMPTOM * AUTO HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - No response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Auto headlamp signal circuit shorted to ground - Electrochromic mirror defective - sensor stuck ON (default) - BCM defective - auto headlamp sensor stuck ON Auto Headlamps Will Not Turn On SYMPTOM * AUTO HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - NO response (BCM) - CCD bus failure - NO response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Electrochromic mirror defective (default) - BCM defective - auto headlamp sensor Fog Lamps Will Not Turn Off SYMPTOM * FOG LAMPS WILL NOT TURN OFF Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2692 POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp switched ground circuit shorted to ground - Headlamp switch defective - foglamp switched ground Fog Lamps Will Not Turn On SYMPTOM * FOG LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp bulbs open - Fog lamp relay control circuit open - Fog lamp relay output circuit open - Fog lamp relay defective, open - Multifunction dimmer switch defective (open) default - Fog lamp switched ground circuit open - BCM defective - Headlamp relay control - Multifunction switch defective (fog lamp relay control) default - Headlamp relay control circuit (foglamps) open Headlamps Will Not Turn Off SYMPTOM * HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch sense circuit shorted to ground - Headlamp relay control circuit shorted to ground - Low beam relay control circuit shorted to ground - Low beam relay control circuit (QUAD) shorted to ground - Low beam headlamp relay (QUAD) defective, shorted - Low beam headlamp relay defective (shorted) by default - PDC defective (low beam headlamp relay connector shorted) - Headlamp switch defective - switch sense - BCM defective (headlamp switch sense function) by default - BCM defective (low beam relay control shorted) by default Headlamps Will Not Turn On SYMPTOM * HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Both low beam fuses open - Fused low beam output circuit open (both lamps inoperative) - Fused low beam output circuit open (one lamp inoperative) - Headlamp defective (by default) - Headlamp fuse open - Headlamp switch sense circuit open - Headlamps defective (by default) - Multifunction switch defective (default) - Headlamp relay control circuit open - Low beam relay control circuit (Chrysler) open - Low beam relay control circuit open - Low beam headlamp relay defective (by default) - Low beam relay defective - relay control function - PDC defective - B(+) circuit at low beam fuse terminal - Power Distribution Center defective (low beam relay CAV A) - Power Distribution Center defective (low beam relay CAV B) - Headlamp switch defective (by default) - BCM defective - headlamp switch sense function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2693 - BCM defective - headlamp switch sense stuck open - BCM defective - low beam relay control open Park Lamps Will Not Turn Off SYMPTOM * PARK LAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Park lamp relay control circuit shorted to ground - Park lamp relay output circuit shorted to voltage - Park lamp switch sense circuit shorted to ground - Park lamp relay defective - control shorted (by default) - Headlamp switch defective - shorted - BCM defective - park lamp switch sense closed (by default) Park Lamps Will Not Turn On SYMPTOM * PARK LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Fused park lamp output circuit open - Park lamp bulb defective (by default) - Park lamp fuse in PDC open - Both park lamp fuses open - Park lamp fuse open - Park lamp relay control circuit open - Park lamp relay output circuit open - Park lamp switch sense circuit open - Park lamp relay defective (control function) - PDC defective - other B(+) cavity - PDC defective - park lamp relay connector, fused B(+) - Headlamp switch defective - park lamps (by default) - BCM defective - park lamp switch sense stuck open - BCM defective - park lamp switch sense function - BCM defective - parklamp control function (by default) ABS Warning Lamp SYMPTOM * ABS WARNING LAMP POSSIBLE CAUSES - BCM connector observable defect - CAB connector observable defect - Fused ignition switch output circuit open - ABS warning lamp defective - ABS warning lamp driver circuit open - ABS warning lamp driver circuit shorted to ground - ABS warning lamp flashing - BCM defective - CAB defective Airbag Warning Lamp SYMPTOM * AIRBAG WARNING LAMP POSSIBLE CAUSES - Airbag warning lamp failure All Warning Lamps Out SYMPTOM * ALL WARNING LAMPS OUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2694 POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Information Center defective Engine Temperature Warning Lamp SYMPTOM * ENGINE TEMPERATURE WARNING LAMP POSSIBLE CAUSES - Engine temperature lamp staying on - Temperature lamp not working - Engine temperature lamp/bulb defective - Fused ignition switch output circuit open - Defective BCM - Engine temperature warning lamp driver circuit open - Temperature warning lamp driver circuit shorted to ground - Information Center defective - Body Control Module defect - Defective Information Center High Beam Indicator Lamp SYMPTOM * HIGH BEAM INDICATOR LAMP POSSIBLE CAUSES - Headlamps inoperative - Fused right highbeam output circuit open - Ground circuit open - High beam indicator bulb defective - Defective Information Center Low Oil Pressure Warning Lamp SYMPTOM * LOW OIL PRESSURE WARNING LAMP POSSIBLE CAUSES - Oil pressure low - Oil warning lamp/bulb defective - Oil level low - Defective oil pressure switch - Oil pressure switch sense circuit shorted to ground - Oil pressure switch sense circuit open - Oil pressure switch defective - BCM defective - Defective Information Center Red Brake Warning Lamp SYMPTOM * RED BRAKE WARNING LAMP POSSIBLE CAUSES - Park brake pedal problem - Vehicle equipped antilock brakes - Brake fluid level low - Red brake warn lamp/bulb defective - Ground circuit open - Brake fluid level switch defective - Defective ignition switch - Defective park brake switch - Red brake warning lamp circuit open - Red brake warning lamp circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2695 - Information Center faulty - Ignition switch defective - Red brake warning lamp driver circuit open - Red brake warning lamp driver circuit faulty Service Engine Soon Lamp SYMPTOM * SERVICE ENGINE SOON LAMP POSSIBLE CAUSES - DTC's are present - Bulb & socket defective - Service Engine Soon indicator lamp driver circuit open - Service Engine Soon indicator lamp circuit shorted to ground - Defective Information Center circuit board - Powertrain Control Module defective Turn Signal Indicator Lamp SYMPTOM * TURN SIGNAL INDICATOR LAMP POSSIBLE CAUSES - Turn signal lamps inoperative - Ground circuit open - Left turn signal circuit open - Right turn signal circuit open - Turn signal bulbs defective - Junction Block defective - BCM defective - Information Center defective Vehicle Theft Alarm Indicator SYMPTOM * VEHICLE THEFT ALARM INDICATOR POSSIBLE CAUSES - Vehicle theft alarm indicator defective All Gauges Inoperative SYMPTOM * ALL GAUGES NOT OPERATING POSSIBLE CAUSES - BCM instrument cluster circuit output defective - Instrument Cluster PC board defective - DRB shows ignition unlock closed - No response - CCD bus instrument cluster - Body computer odometer failure - RAM test failure - ROM test failure Cluster Illumination SYMPTOM * CLUSTER ILLUMINATION POSSIBLE CAUSES - No response - CCD bus instrument cluster - Headlamp switch ground circuit defective - Inoperative lamp defective - Headlamp switch defective - Junction block defective - Dimmer switch signal circuit open - Dimmer switch signal circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2696 - Instrument panel lamps driver circuit shorted to ground - Panel lamps driver circuit open - Park lamps not lighting - Instrument Cluster circuit board defective - BCM dimmer switch signal circuit output faulty - BCM defective - BCM defective by default - Body computer odometer failure - BCM dimmer switch signal circuit defective - Illumination panel fuse OK - Inoperative lamp ground circuit - RAM test failure - ROM test failure Cluster Warning Lamps Odometer and PRNDL Display SYMPTOM * CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY POSSIBLE CAUSES - Any one lamp/bulb defective - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Body computer odometer failure DTC - No response - CCD bus instrument cluster - Washer fluid level switch defective - BCM washer fluid switch sense circuit input defective - All segments fail to light - Faulty odometer and PRNDL lamp - Generator lamp failure - Instrument cluster printed circuit board defective Gauges Not Returning to Zero With Key Off SYMPTOM * GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF POSSIBLE CAUSES - Fused B(+) circuit open - No response - CCD bus instrument cluster - Instrument Cluster PC board defective - Body computer odometer failure - RAM test failure - ROM test failure One Gauge Not Operating Properly SYMPTOM * ONE GAUGE OPERATING IMPROPERLY POSSIBLE CAUSES - DRB reads active on the bus - DRB reads no vehicle speed sense signal code - IOD fuse is loose in junction block - Speedometer calibration out - Any one lamp/bulb defective - DRB reading not matching RPM - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Washer fluid level switch defective - Gauge pack defective - Speedometer/Odometer gauge pack defective - Tachometer calibration out - Cooling system condition faulty - DRB reads coolant temperature sensor code Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2697 - DRB reads engine temperature accurately - BCM instrument cluster circuit output defective - Body Control Module defective - Gauge pack defective - Instrument Cluster printed circuit board defective - DRB shows ignition unlock closed - BCM washer fluid level switch sense circuit input defective - All segments fail to light - BCM temperature gauge input defective - Faulty odometer and PRNDL lamp - Generator lamp failure - PCM defective - Pinion factor failure Trip and Rest Button(S) SYMPTOM * TRIP AND RESET BUTTON(S) POSSIBLE CAUSES - Trip & reset button(s) defective Courtesy Lamps Inoperative W/Dome Lamp Switch SYMPTOM * COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH POSSIBLE CAUSES - Courtesy lamp switch sense circuit open - Headlamp switch defective - courtesy lamp function open - BCM defective - courtesy lamp switch sense (by default) - BCM defective - dome lamp switch function Courtesy Lamps Inoperative With Any Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH ANY DOOR POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay control circuit open - Switched courtesy lamp relay control circuit open - Junction block defective - lamp relay fused B(+) (CAV 87) open - Courtesy lamp relay defective - coil open - Junction block defective - lamp relay fused B(+) (CAV 30) open - Junction block defective - lamp relay fused B(+) (CAV 86) Open - Headlamp switch defective - open - BCM defective - lamp relay control function (by default) - BCM defective - driver door ajar switch status Courtesy Lamps Inoperative With Driver Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR POSSIBLE CAUSES - Driver door ajar switch defective, open - Driver door ajar switch sense circuit open - Left front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Left Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR POSSIBLE CAUSES - Left sliding door ajar switch sense circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2698 - Left sliding door ajar ground circuit open - Left sliding door ajar switch defective, open - BCM defective Courtesy Lamps Inoperative With Liftgate SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LIFTGATE POSSIBLE CAUSES - Liftgate ground circuit open - Liftgate ajar switch open - ajar switch disconnected - Liftgate ajar switch sense circuit open - BCM defective, open Courtesy Lamps Inoperative With Passenger Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR POSSIBLE CAUSES - Passenger door ajar switch defective, open - Passenger door ajar switch sense circuit open - Right front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Right Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR POSSIBLE CAUSES - Right sliding door ajar switch defective, open - Right sliding door ajar switch sense circuit open - Right sliding door ajar ground circuit open - BCM defective, open Courtesy Lamps On at All Times SYMPTOM * COURTESY LAMPS ON AT ALL TIME POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay output circuit shorted to B(+) - Courtesy lamp relay control circuit shorted to ground - Switched courtesy lamp relay control circuit shorted to ground - Courtesy lamp relay defective - coil shorted - Headlamp switch shorted - BCM defective - relay control shorted (by default) Illuminated Entry Inoperative With Driver Door Key Cylinder SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER POSSIBLE CAUSES - Driver door key switch unlock position stuck - Driver door key cylinder switch defective - Driver door key switch sticking Illuminated Entry Inoperative With RKE Transmitter SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2699 - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective unlock switch - RKE module default replacement - RKE module defective CMTC Avg MPH/Fuel Economy Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR WRONG POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative CMTC Elapsed Time Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective BCM / Indicator lights CMTC Fails to Respond to Instrument Cluster Dimming SYMPTOM * COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Trip Odometer Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE/WRONG. POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative Compass/Mini-Trip Computer Displaying OC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING OC POSSIBLE CAUSES - Open sensor ground circuit - Ambient Temperature Sensor defective - Open Ambient Temperature Sensor signal circuit - Defective Compass/Mini-Trip Module - sensor ground circuit. Compass/Mini-Trip Computer Displaying SC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING SC POSSIBLE CAUSES - Defective Ambient Temperature Sensor - Ambient Temperature Sensor signal circuit shorted to ground - Compass/Mini-Trip Module default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2700 Compass/Mini-Trip Computer Segments Fail to Light SYMPTOM * COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - segments fail to light Compass/Mini-Trip Computer Shows Failed SYMPTOM * COMPASS/MINI-TRIP COMPUTER SHOWS FAILED POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - shows failed Compass/Mini-Trip Computer Switch Inoperative SYMPTOM * COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Incorrect Ambient Temperature Readings SYMPTOM * INCORRECT AMBIENT TEMPERATURE READINGS POSSIBLE CAUSES - Open sensor ground - defective CMTM - Sensor ground circuit partial short to ground - Defective Ambient Temperature Sensor/Road test - Ambient Temperature Sensor signal circuit partial short - Ambient Temperature Sensor signal circuit shorted - Defective Compass/Mini-Trip Module - Defective Compass/Mini-Trip Module sensor ground circuit Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH POSSIBLE CAUSES - Junction block defective - Door unlock relay output circuit open - Door unlock relay output circuit resistance low Additional All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door unlock relay control inoperative at BCM - Door unlock relay defective - Door unlock relay coil resistance out of tolerance - Door unlock relay output circuit shorted to ground Additional All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2701 POSSIBLE CAUSES - Passenger door switch MUX shorted to battery - Door lock switch resistance high in unlock position - Driver door switch MUX circuit shorted to battery - Liftgate switch MUX shorted to battery - BCM door lock relay control circuit inoperative - Liftgate switch MUX at BCM defective - Door lock relay control ground circuit open - Door lock relay defective - Fuse # 26 defective - Fused B(+) circuit open - Fused B(+) circuit shorted to ground - Ground circuit open at door lock relay connector Additional All Doors Fail to Lock and Unlock From One Switch SYMPTOM ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH POSSIBLE CAUSES - Door key cylinder switch connector circuit ground circuit open - Door key cylinder switch defective - Liftgate key cylinder switch defective - Liftgate switch MUX shorted to battery - Door switch MUX circuit to BCM open - Driver door switch MUX circuit open at BCM connector - Liftgate switch MUX circuit open at BCM connector - Liftgate switch MUX circuit to BCM open - Passenger door switch MUX circuit open at BCM connector - Passenger door switch MUX circuit to BCM open - Door lock switch connector ground circuit open - Door lock switch defective - Door lock switch MUX circuit open - Door locks inoperative from key cylinder switch - Door switch MUX circuit shorted to battery Additional All Doors Failing to Lock From Any Switch SYMPTOM ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door lock relay control circuit from BCM fails - Key - in ignition switch circuit to BCM defective - Door lock relay does not operate - Door lock relay coil resistance out of tolerance - Door lock relay output shorted to ground - Ignition switch defective - Key - in ignition switch sense circuit shorted to ground Additional Driver Door (w/RKE) Failing to Unlock From Any SW SYMPTOM ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Driver door unlock relay coil resistance out of tolerance - Driver door unlock relay defective - Driver door unlock relay output circuit shorted to ground - Voltage too low at junction block fused B(+) circuit Additional One Door Fails to Lock and Unlock From Any Switch SYMPTOM ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2702 POSSIBLE CAUSES - RKE equipped door lock fails to lock & unlock - Door lock motor defective - Driver unlock relay ground open in junction block - Door lock relay output circuit open - Door unlock relay output circuit open - Driver door unlock relay open All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective door unlock switch - RKE module default replacement - RKE module defective All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Defective door lock switch - Defective unlock switch All Doors Fail to Lock and Unlock From One Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Lock From Any Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2703 - Defective unlock switch All Doors Failing to Lock From One Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Unlock From One Switch SYMPTOM * ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Automatic Door Locks Do Not Lock Over 15 MPH SYMPTOM * AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH POSSIBLE CAUSES - Link to body communication bus inoperative - TPS malfunction causes door lock problem - VSS malfunction causes door lock problem - Auto door lock not enabled Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - BCM defective - BCM sends wrong key - in ignition status - BCM a connector terminals damaged - Ignition switch open - Key - in ignition switch ground circuit open - Key - in ignition switch sense circuit open Driver Door (w/RKE) Failing to Unlock From Any Switch SYMPTOM * DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch One Door Fails to Lock and Unlock From Any Switch SYMPTOM * ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2704 This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Remote Keyless Entry Problem SYMPTOM * RKE PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - RKE module default replacement - RKE module defective Front Wiper Operating Constantly W/Switch In Off Position SYMPTOM * FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION POSSIBLE CAUSES - Front wiper ON/OFF relay control circuit shorted to ground - Defective wiper ON relay/substitute relay - Defective multifunction switch/voltage - High/Low wiper relay HI speed output circuit shorted to voltage - High/Low wiper relay LO speed output circuit shorted to voltage - Defective BCM - 100 ohms default Front Wipers Not Parking In Off Position SYMPTOM * FRONT WIPERS NOT PARKING IN OFF POSITION TEST NOTE This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN POSSIBLE CAUSES - Wiper park switch toggle closed/open - Open wiper park switch sense circuit - Defective BCM - wiper park switch - Defective wiper motor/wiper park switch Front Wipers Not Working at All SYMPTOM * FRONT WIPERS NOT WORKING AT ALL POSSIBLE CAUSES - Open wiper on relay control circuit - BCM/wiper relay - Defective wiper ON relay - BCM/ground - Front wiper switch MUX circuit shorted to ground - Open front wiper switch MUX circuit between switch and BCM - Defective High/Low wiper relay - relay connector - Defective multifunction switch/front wiper switch - High/Low wiper relay HI speed output circuit shorted to ground - High/Low wiper relay LO speed output circuit shorted to ground - Open ground circuit/lights - Open High/Low relay LO speed output circuit between High/Low relay and wiper motor - Open fused ignition switch output circuit/multifunction switch - Defective Power Distribution Center - relay connector Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2705 - Defective Power Distribution Center - front wiper relay - Defective Power Distribution Center - wiper ON relay - Defective Power Distribution Center - wiper relay - Defective Power Distribution Center - H/L relay - Defective Power Distribution Center - B(+) circuit. - Defective wiper motor/harness - Defective BCM/wiper relay - Defective BCM/front wiper MUX - Defective BCM/sensors - Defective wiper motor ground circuit. Front Wipers Not Working In High Speed Mode SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE POSSIBLE CAUSES - Open HI/LO wiper relay control circuit - Defective HI/LO wiper RELAY - Wiper switch - Open wiper HI/LO relay HI speed output circuit - Defective multi - FUNCT switch/ ground circuit - Defective power DIST CNTR-H/L WPR RLY - Defective wiper Motor/HI speed output circuit - Open ground circuit/Multi - Function switch Front Wipers Not Working In Intermittent Mode SYMPTOM * FRONT WIPERS NOT WORKING IN INTERMITTENT MODE POSSIBLE CAUSES - Defective multifunction switch/positions - Defective BCM/wiper positions - Defective multifunction switch/Default Front Wipers Not Working In Low Speed Mode SYMPTOM * FRONT WIPERS NOT WORKING IN LOW SPEED MODE POSSIBLE CAUSES - High/Low wiper relay control circuit shorted to ground - Defective High/Low wiper relay - fused ignition switch - Open High/Low wiper relay - LO speed output circuit - Defective wiper motor/LO speed output circuit Rear Washer Motor Inoperative SYMPTOM * REAR WASHER MOTOR INOPERATIVE POSSIBLE CAUSES - Open rear washer motor control circuit - Defective rear washer motor/jumper - Open fused ignition switch output circuit/voltage - Defective HVAC Control Module / 3.8 volts - Defective BCM - washer motor operate Rear Wiper Not Parking In the Off Position SYMPTOM * REAR WIPER NOT PARKING IN THE OFF POSITION POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective HVAC Control Module/switch indicator lights - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2706 - Defective BCM/washer motor run - Defective BCM/cycle on default - Defective BCM/rear wiper switch voltage - Defective rear wiper motor/test light Rear Wiper Not Working at All SYMPTOM * REAR WIPER NOT WORKING AT ALL POSSIBLE CAUSES - Open rear wiper motor control circuit - Open rear wiper switch MUX circuit - Open ground circuit/rear wiper motor - Open fused ignition switch output circuit/fuse # 6 - Open fused ignition switch output circuit/fuse # 8 - Shorted fused ignition switch output circuit/fuse # 6 - Defective rear wiper motor/motor control - Defective HVAC Control Module/default - Defective HVAC Control Module/rear wiper switch MUX - Defective BCM/rear wiper switch MUX - Defective BCM/rear wiper motor - Defective HVAC Control Module/21-Way connector Rear Wiper Not Working In the Intermittent Mode SYMPTOM * REAR WIPER NOT WORKING IN THE INTERMITTENT MODE POSSIBLE CAUSES - Defective rear wiper motor/intermittent switch - Defective HVAC Control Module/indicator light - Defective HVAC Control Module/rear wiper switch - Defective BCM/test light default Rear Wiper/Wash Working Continuously SYMPTOM * REAR WIPER/WASH WORKING CONTINUOUSLY POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default - Defective BCM/washer motor run - Defective BCM/rear wiper switch voltage Wiper/Wash Function Not Working Properly SYMPTOM * WIPER/WASH FUNCTION NOT WORKING PROPERLY POSSIBLE CAUSES - Defective washer motor/washer pump control - Operate wipers - Open washer pump control circuit - Defective multifunction switch/washer pump control - Open fused ignition switch output circuit - Defective junction block/BCM - Defective junction block/block connector - Defective BCM/junction block - Defective BCM/stalk switch - Fused ignition switch output circuit shorted to ground - Open washer pump control circuit/multifunction switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2707 Body Control Module: Component Tests and General Diagnostics Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2708 Body Control Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2709 Body Control Module: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) Body Control Module - Location 4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Refer to Instrument Panel and Systems, Body Control Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2710 Body Control Module: Tools and Equipment DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Power Distribution Center & Powertrain Control Module (PCM) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2727 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2729 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2730 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2731 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2732 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2733 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2734 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2735 Powertrain Control Module C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2736 Powertrain Control Module: Description and Operation OPERATION Powertrain Control Module The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet changing engine operating conditions. During the crank-start period the PCM advances ignition timing a set amount. During engine operation, the amount of spark advance provided by the PCM is determined by the following input factors: available manifold vacuum - barometric pressure - engine coolant temperature - engine RPM - throttle position The PCM also regulates the fuel injection system. Refer to the Fuel Injection. The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2737 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection Power Distribution Center Retaining Screws 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket. Battery Heat Shield 3. Remove heat shield from battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2738 Battery Clamp 4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle. PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2739 PCM 40-way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both way connectors. PCM Removal/Installation 9. Remove 3 screws holding PCM to fender. 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2743 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2746 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2747 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2748 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2749 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2750 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2751 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2752 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2753 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2754 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2755 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2756 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2757 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2758 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2760 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2762 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2763 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2765 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2766 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2769 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 2770 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation OPERATION The temperature sensor, in the PCM, is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2778 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2779 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2780 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2781 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2782 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2783 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2784 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Temperature Sensor 7 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2788 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2789 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2790 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2791 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40° F to 265° F). The engine coolant temperature sensor provides an input voltage to the PCM. As coolant temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle speeds until normal operating temperatures are reached. The engine coolant sensor is also used for cooling fan control. Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2792 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant Temperature Sensor 1. With the key off, disconnect wire harness connector from coolant temperature sensor. Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter should read as follows: a. ECT STET at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2793 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor The sensor is installed next to the thermostat housing. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2797 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2798 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2799 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2800 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2801 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2802 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The level sensor is attached to the side of the fuel pump module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2806 Fuel Level Sensor: Description and Operation DESCRIPTION The level sensor is attached to the side of the fuel pump module. The level sensor consists of a float, an arm, and a variable resistor. OPERATION As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2807 Fuel Level Sensor: Testing and Inspection This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Level Sensor Diagnosis The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2808 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector. NOTE: The pump module harness on TOP of flange is not serviceable or removable. Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2809 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Level Sensor Removal/Installation 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2810 Groove In Back Side Of Level Sensor 2. Wrap wires into groove in back of level sensor. Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2814 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2815 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2816 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2817 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Sensor Tightening Torque 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2821 MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2822 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2823 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. MAP Sensor MAP Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2824 MAP Sensor The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The sensor connects electrically to the PCM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2825 Manifold Pressure/Vacuum Sensor: Testing and Inspection To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. MAP Sensor Connector 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3. With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (± 0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If not OK, repair or replace the wire harness as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2826 Manifold Pressure/Vacuum Sensor: Service and Repair Map Absolute Pressure Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the intake manifold. INSTALLATION 1. Reverse the above procedure for installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Oxygen Sensor 27 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2832 Oxygen Sensor: Locations Oxygen Sensor(s) Heated Oxygen Sensor Downstream Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2833 Oxygen Sensor: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2834 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2835 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2836 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR Heated Oxygen Sensor Heated Oxygen Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2837 Heated Oxygen Sensor The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2838 Oxygen Sensor: Testing and Inspection Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical connector from each oxygen sensor. The white wires in the sensor connector are the power and ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement REMOVAL 1. Raise and support vehicle. WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. Oxygen Sensor Grommet Cover 2. Remove grommet cover to expose connector. Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector. Oxygen Sensor Removal/Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2841 INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2842 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Upstream Heated Oxygen Sensor The oxygen sensor is installed in the exhaust manifold . CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2846 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2847 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2848 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2849 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2850 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 2855 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 2856 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2857 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2858 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2859 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2860 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2861 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2885 Vehicle Speed Sensor: Description and Operation Description The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are threaded into the transaxle case and are considered primary inputs to the Trans- mission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2889 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2890 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2891 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2892 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2893 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 2898 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 2899 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2900 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2901 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2902 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2903 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2904 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2916 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2917 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2918 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2919 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2920 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2928 Vehicle Speed Sensor: Description and Operation Description The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are threaded into the transaxle case and are considered primary inputs to the Trans- mission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation BATTERY VOLTAGE-PCM INPUT The PCM monitors the battery voltage input to determine fuel injector pulse width and generator field control. If battery voltage is low the PCM will increase injector pulse width (period of time that the injector is energized). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation There is no regularly scheduled maintenance on any Chrysler catalytic converter. If damaged, the converter must be replaced. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country. The combustion reaction caused by the catalyst releases additional heat in the exhaust system. Causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel igniting when passing through the converter. The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan temperatures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2936 Catalytic Converter: Service and Repair WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. REMOVAL 1. Remove muffler and tailpipe assembly. Downstream Oxygen Sensor 2. Disconnect downstream oxygen sensor from the catalytic converter pipe. 3. Remove catalytic converter to exhaust manifold attaching fasteners. 4. Remove catalytic converter and gasket. INSTALLATION 1. Position new gasket onto manifold flange and install catalytic converter. Tighten fasteners to 28 Nm (250 inch lbs.). 2. Connect downstream oxygen sensor. 3. Install muffler and tailpipe assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2941 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2942 Canister Purge Solenoid: Description and Operation Proportion Purge Solenoid OPERATION All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. DUTY CYCLE EVAP CANISTER PURGE SOLENOID-PCM OUTPUT The duty cycle EVAP purge solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time the solenoid energizes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2943 Duty Cycle EVAP Purge Solenoid A rubber boot covers the duty cycle EVAP purge solenoid. The solenoid attaches to a bracket mounted to the right engine mount. The top of the solenoid has the word TOP on it. The solenoid will not operate properly unless it is installed correctly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2944 Canister Purge Solenoid: Service and Repair REMOVAL Proportional Purge Solenoid Valve 1. Remove vacuum hose and electrical connector from solenoid. 2. Pull solenoid up to remove it from mounting bracket. INSTALLATION Reverse above procedure for installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Evaporative Canister The canister is attached to the frame under the driver's seat. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2948 Evaporative Emission Control Canister: Description and Operation DESCRIPTION Evaporative Canister The canister is attached to the frame under the driver's seat. OPERATION All vehicles use a sealed, maintenance free, evaporative (charcoal) canister. Fuel tank vapor vents into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The canister proportional purge solenoid allows the canister to be purged at predetermined intervals and engine conditions. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak Detection Pump Misdiagnosis Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2953 Leak Detection Pump: Specifications LDP Bolts 9.5 - 14 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2954 Leak Detection Pump: Locations Leak Detection Pump The Leak Detection Pump (LDP) is located under the driver's side in the cast cradle under the steering gear. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2955 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2956 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2957 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2958 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2959 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2960 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2961 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2962 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2963 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2964 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2965 Leak Detection Pump: Service and Repair REMOVAL Leak Detection Pump The Leak Detection Pump LDP. is located under the driver's side in the cast cradle under the steering gear. 1. Raise and support vehicle on a hoist. Leak Detection Pump Connector Lock 2. Push locking tab on connector to unlock. 3. Push down on connector latch and pull connector from pump. 4. Remove hoses. 5. Remove bolts holding LDP and bracket to cradle. 6. Remove bracket from LDP. INSTALLATION 1. Install LDP to bracket. 2. Install LDP and bracket to cradle. Torque bolts to 9.5-14 Nm (85-125 in. lbs.). Before installing hoses to LDP, make sure they are not cracked or split. If a hose leaks, it will cause the Check Engine Lamp to illuminate. 3. Install hoses to LDP. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2966 4. Plug electrical connector into LDP. 5. Push connector locking tab into place. 6. Using DRB scan tool, verify proper operation of LDP. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation ELECTRONIC EGR TRANSDUCER SOLENOID-PCM OUTPUT EGR Solenoid EGR Solenoid EGR Solenoid The electronic EGR transducer contains an electrically operated solenoid and a back-pressure transducer. The PCM operates the solenoid. The PCM determines when to energize the solenoid. Exhaust system back-pressure controls the transducer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation > Page 2971 When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to the transducer when the PCM de-energizes the solenoid. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations EGR Control Solenoid: Locations EGR Solenoid Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 2975 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Tube to Intake Manifold Screws 22 Nm EGR Tube Mounting Bolts 22 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2979 EGR Tube: Service and Repair REMOVAL EGR Tube 1. Remove EGR tube attaching bolts from intake and exhaust manifolds. 2. Clean intake and exhaust manifold gasket surfaces. Discard old gasket. 3. Check for signs of leakage or cracked surfaces on either manifolds or tube. Repair or replace as necessary. INSTALLATION 1. Loosely assemble EGR tube and new gaskets into place on intake and exhaust manifolds. 2. Tighten mounting bolts to 22 Nm (200 in. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts 22 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2983 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Valve Leakage Test EGR Valve: Testing and Inspection EGR Valve Leakage Test This is not to be used as a complete test of the EGR system. EGR Valve And EGR Valve - Typical If the engine will not idle, dies out on idle, or idle is rough or slow, the poppet valve at the base of the EGR valve may be leaking in the closed position. 1. The engine should be off for the following test. 2. Disconnect the rubber hose from the fitting at the top vacuum motor. side of the EGR valve. a. Connect a hand-held vacuum pump to this fitting. b. Apply 15 inches of vacuum to the pump. c. Observe the gauge reading on the pump. d. If vacuum falls off, the diaphragm in the EGR valve has ruptured. e. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. Refer to EGR Valve Removal/installation. f. Proceed to the next step. 3. A small metal fitting back-pressure fitting. is located at the base of the EGR valve. A rubber back-pressure hose connects it to the back-pressure fitting on the EGR valve control. Disconnect this rubber hose at the EGR valve fitting. 4. Remove the air cleaner housing from the throttle body. 5. Using compressed air, and using an air nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal back-pressure fitting on the EGR valve. 6. By hand, open the throttle to the wide open position. Air SHOULD NOT BE HEARD emitting from the intake manifold while applying air pressure at the back-pressure fitting. 7. If air CAN BE HEARD emitting from the intake manifold, the poppet valve is leaking at the bottom of the EGR valve. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. Refer to EGR Valve Removal/installation. Do not attempt clean the old EGR valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Valve Leakage Test > Page 2986 EGR Valve: Testing and Inspection EGR Valve Control (Transducer) Test Testing electrical solenoid portion of valve This is not to be used as a complete test of the EGR system. Electrical operation of the valve should be checked with the DRB scan tool. Refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool. Replace solenoid if necessary, unit serviced only as an assembly. Testing vacuum transducer portion of valve The first part of this test will determine if the transducer diaphragm at the back-pressure side of the valve has ruptured or is leaking. The second part of the test will determine if engine vacuum full-manifold. is flowing from the inlet to the outlet side of the valve. This is not to be used as a complete test of the EGR system. EGR Valve And EGR Valve - Typical 1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve. 2. Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If vacuum falls off, the valve diaphragm is leaking. 5. Replace the Complete EGR valve assembly. Proceed to next step for further testing. 6. Reconnect hose to EGR valve. 7. Remove the vacuum supply hose at the vacuum inlet fitting on the EGR solenoid. 8. Connect a vacuum gauge to this disconnected vacuum line. 9. Start the engine and bring to operating temperature. Hold engine speed at approximately 1500 rpm. 10. Check for steady engine vacuum full-manifold. at this hose. 11. If engine vacuum full-manifold. is not present, check vacuum line to engine and repair as necessary before proceeding to next step. 12. Reconnect the rubber hose to the vacuum inlet fitting on the EGR valve. 13. Disconnect the rubber hose at the vacuum outlet fitting on the EGR valve. 14. Connect a vacuum gauge to this fitting. 15. Disconnect the electrical connector at the valve control. This will simulate an open circuit no ground from the PCM. at the valve, activating the valve. A DTC will be set in the PCM that must be erased after testing is complete. 16. Start the engine and bring to operating temperature. 17. Hold the engine speed to approximately 2000 rpm while checking for engine vacuum (full-manifold) at this fitting. To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. It must be high enough to hold the bleed valve in the transducer portion of the valve closed. Have a helper momentarily a second or two. hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the vacuum gauge. Heavy gloves should be worn. Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. 18. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum outlet fitting. Without back-pressure, and engine at Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Valve Leakage Test > Page 2987 approximately 2000 rpm, the gauge reading will be low. This low reading is normal. At idle speed, the gauge reading may be erratic. This is also normal. 19. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the valve. Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. Refer to EGR Valve Removal/installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > Page 2988 EGR Valve: Service and Repair The EGR valve and Electrical EGR Transducer are serviced as an assembly. REMOVAL EGR System 1. Disconnect vacuum tube from electric EGR transducer. Inspect vacuum tube for damage. 2. Remove electrical connector from solenoid. 3. Remove EGR valve bolts from intake manifold. 4. Open EGR transducer clip and remove electric EGR transducer. 5. Remove EGR valve from intake manifold. 6. Clean gasket surface and discard old gasket. Check for any signs of leakage or cracked surfaces. Repair or replace as necessary. INSTALLATION 1. Assemble EGR valve with new gasket onto the intake manifold. 2. Install mounting bolts. Tighten bolts to 22 Nm (200 in. lbs.) torque. 3. Install electric EGR transducer in clip with orientation tab in slot and snap closed. 4. Reconnect vacuum hose and electrical connector to electrical EGR transducer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation OPERATION All engines use filtered air to vent the crankcase. The filtered air is drawn through the resonator assembly located between the air cleaner and throttle body. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation Positive Crankcase Ventilation Valve: Description and Operation OPERATION The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Engine Off Or Engine Backfire-No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. High Intake Manifold Vacuum-Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Moderate Intake Manifold Vacuum-Maximum Vapor Flow During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 2996 Positive Crankcase Ventilation Valve: Testing and Inspection WARNING: APPLY PARKING BRAKE AND/OR BLOCK WHEELS BEFORE PERFORMING ANY TEST OR ADJUSTMENT WITH THE ENGINE OPERATING. PCV Test-Typical With the engine idling, remove the PCV valve from its attaching point. If the valve is operating properly, a hissing noise will be heard and a strong vacuum felt when placing a finger over the valve inlet. With the engine off, shake the valve. The valve should rattle when shaken. Replace the valve if it does not operate properly. Do not attempt to clean the PCV valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Key On, Engine Off .............................................................................................................................. ......................................... (approx.) 338 kPa (49 psi) Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3002 Fuel Pressure: Capacity Specifications Information not supplied by the manufacturer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3006 Fuel Pressure Release: Service and Repair WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. Fuel Pressure Test Port Releasing Fuel Pressure 3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. 5. Replace Pressure test port cap when finished doing pressure test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3010 Idle Speed: Testing and Inspection 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. PCV Valve 4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6. Air Metering Fitting 6457 a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b. Disconnect the idle purge line from the throttle body nipple. 7. a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector. 8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 10. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum air-flow is set correctly. IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above 1000 Miles = 575-875 RPM 12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3011 b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle purge line. 16. Remove DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal Retaining Nuts 12 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3015 Accelerator Pedal: Service Precautions CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3016 Accelerator Pedal: Service and Repair CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. REMOVAL 1. Working from the engine compartment, remove the throttle control shield. 2. Hold the throttle body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam. Accelerator Pedal And Throttle Cable-Front View Accelerator Pedal And Throttle Cable-Rear View 3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft. 4. Working from the engine compartment, remove nuts from accelerator pedal attaching studs. Remove assembly from vehicle. INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 Nm (105 in. lbs.) torque. 2. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft. 3. From the engine compartment, hold the throttle body lever in the wide open position and install the throttle cable. Install the throttle control shield. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Air Inlet Resonator 1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves together. Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3021 Air Cleaner Element 4. Remove element from air cleaner housing. INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Rating Fuel Rating Fuel Unleaded fuel having a minimum octane rating of 87. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Page 3025 Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. CAUTION: DO NOT use gasoline containing methanol. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3030 Fuel Pressure Release: Service and Repair WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. Fuel Pressure Test Port Releasing Fuel Pressure 3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. 5. Replace Pressure test port cap when finished doing pressure test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications Fuel Hose Clamp: Specifications Fuel Hose Clamps 1 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 3034 Fuel Hose Clamp: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 3035 Fuel Hose Clamp: Description and Operation FUEL TUBES/LINES/HOSES AND CLAMPS Also refer to Quick-Connect Fittings. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure and leaks are not present. The component should be replaced immediately if there is any evidence of degradation that could result in failure. Never attempt to repair a plastic fuel line/tube. Replace as necessary. Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Tighten hose clamps to 3 Nm (25 in. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 3036 Fuel Hose Clamp: Testing and Inspection Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks. Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear. Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI. When installing hoses, ensure that they are routed away from contact with other vehicle components that could rub against them and cause failure. Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and avoid heat sources. The hose clamps have rolled edges to prevent the clamp from cutting into the hose. Only use clamps that are original equipment or equivalent. Other types of clamps may cut into the hoses and cause high pressure fuel leaks, Tighten hose clamps to 1 Nm (10 in. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector Resistance .............................................................................................................................. .......................................... 12 ohms at 20 ° C (68 ° F) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3041 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3042 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3043 Fuel Injector: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3044 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3045 Fuel Injector: Description and Operation DESCRIPTION Fuel Injector Location - Typical The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port. OPERATION Fuel Injector The fuel injectors are 12 ohm electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. Fuel injectors are not interchangeable between engines. Fuel Injector Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3046 FUEL INJECTORS-PCM OUTPUT The fuel injectors are 12 ohm electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The injectors are positioned in the intake manifold. Fuel Injector Location-Typical The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port. The fuel injectors are operated by the PCM. They are energized in a sequential order during all engine operating conditions except start up. The PCM initially energizes all injectors at the same time. Once PCM determines crankshaft position, it begins energizing the injectors in sequence. The Automatic Shutdown (ASD) relay supplies battery voltage to the injectors. The PCM provides the ground path for the injectors. By switching the ground path on and off, the PCM adjusts injector pulse width. Pulse width is the amount of time the injector is energized. The PCM adjusts injector pulse width based on inputs it receives. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3047 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3048 Fuel Injector: Service and Repair The fuel rail must be removed first. Refer to Fuel Injector Rail Assembly Removal. REMOVAL 1. Disconnect injector wiring connector from injector. Fuel Injector And Rail-Typical 2. Position fuel rail assembly so that the fuel injectors are easily accessible. 3. Rotate injector and pull injector out of fuel rail. The clip will stay on the injector. 4. Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to prevent damage. Replace the injector clip if it is damaged. 5. Repeat for remaining injectors. INSTALLATION 1. Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. Servicing Fuel Injector - Typical 2. Install injector clip by sliding open end into the top slot of the injector. The edge of the receiver cup will slide into the side slots of clip. 3. Install injector top end into fuel rail receiver cap. Be careful not to damage O-ring during installation. 4. Repeat steps for remaining injectors. 5. Connect fuel injector wiring. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions WARNING: - RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. - THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. CAUTION: - Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. - The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 3052 Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS DESCRIPTION Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Refer to the Removal/installation for more information. CAUTION: The interior components (O-rings, spacers) of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Plastic Quick-Connect Fittings Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable O-ring seals. CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick- connect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly. The quick-connect fitting consists of the O-rings, retainer and casing. When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the O-rings seal the tube. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 3053 Fuel Line Coupler: Service and Repair REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. 1. Disconnect negative cable from battery or auxiliary jumper terminal. 2. Perform Fuel Pressure Release Procedure. Refer to the Fuel Pressure Release Procedure. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. INSTALLATION CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. 1. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. 3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. Plastic Quick-Connect Fitting/Fuel Tube Connection 4. The plastic quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed. Do not rely upon the audible click to confirm a secure connection. 5. Connect negative cable to battery or auxiliary jumper terminal. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position. 6. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. TWO-TAB TYPE FITTING Typical Two-Tab Type Quick-Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 3054 CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. Disconnection/Connection 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To disconnect quick-connect fitting, squeeze plastic retainer tabs against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. 5. Inspect quickconnect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery or auxiliary jumper terminal. 10. Start engine and check for leaks, PLASTIC RETAINER RING TYPE FITTING Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Disconnection/Connection 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 3055 4. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. 5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 8. Insert quick-connect fitting into component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 10. Connect negative battery cable to battery or auxiliary jumper terminal. 11. Start engine and check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions Fuel Pressure Regulator: Service Precautions WARNING: FUEL SYSTEM PRESSURE MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT. PERFORM THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 3059 Fuel Pressure Regulator: Description and Operation OPERATION The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 338 kPa (49 psi), 3.31 FFV uses approximately 379 kPa (55 psi). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pressure required to open the return port. The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine vacuum. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 3060 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator The fuel pressure regulator is part of the fuel pump module. Remove the fuel pump module from the fuel tank to access the fuel pressure regulator. Refer to the Fuel Pump Module removal. WARNING: FUEL SYSTEM PRESSURE MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT. PERFORM THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. REMOVAL 1. Spread tangs on pressure regulator retainer. 2. Pry fuel pressure regulator out of housing. 3. Ensure both upper and lower O-rings were removed with regulator. INSTALLATION Fuel Pressure Regulator O-rings 1. Lightly lubricate the O-rings with clean engine oil and place them into opening in pump module. 2. Push regulator into opening in pump module. 3. Fold tangs on regulator retainer over tabs on housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Key On, Engine Off .............................................................................................................................. ......................................... (approx.) 338 kPa (49 psi) Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3066 Fuel Pressure: Capacity Specifications Information not supplied by the manufacturer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3070 Power Distribution Center -- Sheet 8w-10-2 The fuel pump relay is located in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3071 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3072 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit contains a 9 amp fuse. The fuse is located in the PDC. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3073 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3074 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Inlet Strainer Removal 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer. 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage Technical Service Bulletin # 895 Date: 020101 Recall - Potential Fuel Rail Seal Leakage January 2002 Dealer Service Instructions for Safety Recall No. 895 -- Fuel Rail Seals Models 1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or "L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999). IMPORTANT: Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in this recall. IMPORTANT: Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty records, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine compartment fire. Repair External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3086 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3087 Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD895". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by describing the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Fuel Rail 1. Raise hood. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3088 2. Inspect both of the fuel rail crossover tube joints (Figure 1) 3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. > If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube joints, continue with Section B - Install Fuel Rail Seals. B. Install Fuel Rail Seals 1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only), remove the cover and set it aside. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3089 2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the Scotch-Brite pad and then use compressed air to remove any remaining particles. 3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease seal installation. 4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure to coat the flat ends as well as the two beads. IMPORTANT: Drain any excess oil from the seals. 5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3). NOTE: Both of the seal halves are identical. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3090 6. Seat the seal halves around the joint and then while holding the two seals halves together, install one of the provided clamps around the seal halves (Figure 4). 7. Tighten the clamp to 75 in-lbs (8.5 N.m). 8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3). 9. Seat the seal halves around the joint and then while holding the two seals halves together, install the other clamp around the seal halves (Figure 4). 10. Tighten the clamp to 75 in-lbs (8.5 N.m). 11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the cover must be modified as follows: a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube joint (Figure 5). Discard the clip. b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the mold line on the end of the cover (Figure 5). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3091 c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely. 12. No further action is necessary. Return the vehicle to the customer. C. Replace Fuel Rail Assembly NOTE: Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail replacement. WARNING: The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before replacing the fuel rail. 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure. 3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when pressure is released from the rail. 4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel pressure. 5. Remove the hose from the fuel rail and reinstall the test port cap. 6. Remove the plastic intake manifold cover, if equipped. 7. Remove the air inlet resonator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3092 8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and bracket (Figure 7). 9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Figure 8). 10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3093 11. Disconnect the EGR tube from the intake manifold flange (Figure 10). 12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head. 13. Disconnect the MAP sensor electrical connector (Figure 11). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3094 14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12). WARNING: Wrap a shop towel around the hoses to catch any gasoline spillage. 15. Remove the Direct Ignition System (DIS) coil pack (Figure 13). 16. Remove the generator support bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3095 17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve cover (Figure 14). NOTE: It is not necessary to completely remove the intake plenum from the vehicle. 18. Cover the intake manifold openings. 19. Remove the fuel rail attaching bolts (Figure 15). 20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 21. Disconnect the fuel rail wiring harness from the main engine harness. 22. Remove the fuel rail assembly. 23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors are easily accessible. 24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring harness from the fuel rail. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3096 25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the injector (Figure 17). 26. Remove the upper and lower injector 0-rings from the injectors. 27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil. 28. Install the new upper 0-rings (BLUE) on the top of the injectors. CAUTION: Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result. 29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil. 30. Install the new lower 0-rings (BLACK) on the bottom of the injectors. 31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot of the injector. 32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully seated. Use care so that the upper 0-ring is not damaged during installation. 33. Connect the injector wiring harness to the injectors. 34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail assembly into place until all injectors are seated in their port. 35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22 N.m). 36. Connect the fuel injector wiring harness to the main engine wiring harness. 37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the connector on until it clicks and then pull back to ensure a complete connection. 38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake plenum gasket surfaces. 40. Place the provided intake plenum gasket on the intake manifold. 41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum bolts. Do NOT tighten. 42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3097 43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT tighten. 44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely install the mounting bolts. Do NOT tighten. 45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28 N.m). 46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m). 47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m). 48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10). 49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm). 50. Connect the MAP sensor electrical connector (Figure 11). 51. Connect the vacuum hoses to the intake plenum (Figure 9). 52. Connect the TPS and idle air control motor electrical connectors (Figure 8). 53. Connect the throttle body vacuum connectors (Figure 9). 54. Connect the throttle cable and speed control cable (if equipped) (Figure 7). 55. Install the intake manifold cover (if equipped). 56. Install the air inlet resonator. 57. Connect the negative battery cable. 58. Start the engine and check for any fuel leakage. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3098 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > NHTSA00V268000 > Sep > 00 > Recall 00V268000: Fuel Rail Cracks/Leaks Fuel Rail: Recalls Recall 00V268000: Fuel Rail Cracks/Leaks Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel rail crossover tube, should the existing O-rings continue to degrade. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule. However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage Technical Service Bulletin # 895 Date: 020101 Recall - Potential Fuel Rail Seal Leakage January 2002 Dealer Service Instructions for Safety Recall No. 895 -- Fuel Rail Seals Models 1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or "L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999). IMPORTANT: Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in this recall. IMPORTANT: Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty records, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine compartment fire. Repair External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3108 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3109 Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD895". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by describing the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Fuel Rail 1. Raise hood. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3110 2. Inspect both of the fuel rail crossover tube joints (Figure 1) 3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. > If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube joints, continue with Section B - Install Fuel Rail Seals. B. Install Fuel Rail Seals 1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only), remove the cover and set it aside. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3111 2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the Scotch-Brite pad and then use compressed air to remove any remaining particles. 3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease seal installation. 4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure to coat the flat ends as well as the two beads. IMPORTANT: Drain any excess oil from the seals. 5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3). NOTE: Both of the seal halves are identical. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3112 6. Seat the seal halves around the joint and then while holding the two seals halves together, install one of the provided clamps around the seal halves (Figure 4). 7. Tighten the clamp to 75 in-lbs (8.5 N.m). 8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3). 9. Seat the seal halves around the joint and then while holding the two seals halves together, install the other clamp around the seal halves (Figure 4). 10. Tighten the clamp to 75 in-lbs (8.5 N.m). 11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the cover must be modified as follows: a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube joint (Figure 5). Discard the clip. b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the mold line on the end of the cover (Figure 5). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3113 c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely. 12. No further action is necessary. Return the vehicle to the customer. C. Replace Fuel Rail Assembly NOTE: Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail replacement. WARNING: The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before replacing the fuel rail. 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure. 3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when pressure is released from the rail. 4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel pressure. 5. Remove the hose from the fuel rail and reinstall the test port cap. 6. Remove the plastic intake manifold cover, if equipped. 7. Remove the air inlet resonator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3114 8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and bracket (Figure 7). 9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Figure 8). 10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3115 11. Disconnect the EGR tube from the intake manifold flange (Figure 10). 12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head. 13. Disconnect the MAP sensor electrical connector (Figure 11). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3116 14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12). WARNING: Wrap a shop towel around the hoses to catch any gasoline spillage. 15. Remove the Direct Ignition System (DIS) coil pack (Figure 13). 16. Remove the generator support bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3117 17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve cover (Figure 14). NOTE: It is not necessary to completely remove the intake plenum from the vehicle. 18. Cover the intake manifold openings. 19. Remove the fuel rail attaching bolts (Figure 15). 20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 21. Disconnect the fuel rail wiring harness from the main engine harness. 22. Remove the fuel rail assembly. 23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors are easily accessible. 24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring harness from the fuel rail. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3118 25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the injector (Figure 17). 26. Remove the upper and lower injector 0-rings from the injectors. 27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil. 28. Install the new upper 0-rings (BLUE) on the top of the injectors. CAUTION: Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result. 29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil. 30. Install the new lower 0-rings (BLACK) on the bottom of the injectors. 31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot of the injector. 32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully seated. Use care so that the upper 0-ring is not damaged during installation. 33. Connect the injector wiring harness to the injectors. 34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail assembly into place until all injectors are seated in their port. 35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22 N.m). 36. Connect the fuel injector wiring harness to the main engine wiring harness. 37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the connector on until it clicks and then pull back to ensure a complete connection. 38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake plenum gasket surfaces. 40. Place the provided intake plenum gasket on the intake manifold. 41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum bolts. Do NOT tighten. 42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3119 43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT tighten. 44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely install the mounting bolts. Do NOT tighten. 45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28 N.m). 46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m). 47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m). 48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10). 49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm). 50. Connect the MAP sensor electrical connector (Figure 11). 51. Connect the vacuum hoses to the intake plenum (Figure 9). 52. Connect the TPS and idle air control motor electrical connectors (Figure 8). 53. Connect the throttle body vacuum connectors (Figure 9). 54. Connect the throttle cable and speed control cable (if equipped) (Figure 7). 55. Install the intake manifold cover (if equipped). 56. Install the air inlet resonator. 57. Connect the negative battery cable. 58. Start the engine and check for any fuel leakage. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3120 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > NHTSA00V268000 > Sep > 00 > Recall 00V268000: Fuel Rail Cracks/Leaks Fuel Rail: All Technical Service Bulletins Recall 00V268000: Fuel Rail Cracks/Leaks Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel rail crossover tube, should the existing O-rings continue to degrade. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule. However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3125 Fuel Rail: Specifications Fuel Rail Mounting Bolts 22 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3126 Fuel Rail: Service and Repair WARNING: THE MPI FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 330 kPa (49 PSI), 3.3L USES APPROXIMATELY 379 kPa (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL RAIL OR FUEL INJECTORS. REMOVAL 1. Perform fuel system pressure release procedure. 2. Disconnect negative cable from battery. 3. Remove intake manifold cover. Air Inlet Resonator 4. Remove air inlet resonator. Throttle Cable Attachment 5. Remove throttle cable and speed control cable (if equipped) from throttle lever and bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3127 Electrical And Vacuum Connection To Throttle Body 6. Disconnect idle air control motor and Throttle Position Sensor (TPS) electrical connectors. Vacuum Connections 7. Remove vacuum hose harness from throttle body and intake manifold. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3128 EGR Tube 8. Remove EGR tube to intake manifold flange bolts. 9. Remove cylinder head to intake plenum strut. Map Sensor 10. Disconnect electrical connector from the MAP sensor. 11. Remove engine mounted ground strap. Fuel Line Quick Disconnect Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3129 12. Remove the fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE. Ignition Coils 13. Remove Direct Ignition System (DIS) coils. 14. Remove generator bracket to intake manifold bolt. Intake Manifold Bolts 15. Remove intake mounting manifold bolts and rotate manifold back over rear valve cover. Fuel Rail Attaching Bolts 16. Cover intake manifold with suitable cover when servicing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3130 17. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer bracket to allow fuel tube removal clearance. Camshaft Position Sensor Connector 18. Disconnect camshaft position sensor and engine coolant temperature sensor. Fuel Rail Removal 19. Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports. INSTALLATION 1. Ensure injector holes are clean. Replace O-rings if damaged. 2. Lubricate injector O-rings with a drop of clean engine oil to ease installation. 3. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports. 4. Install the fuel rail mounting bolts. Tighten bolts to 22 Nm (200 in. lbs.) torque. 5. Install fuel tube retaining bracket screw. Tighten screw to 4 Nm (35 in. lbs.) torque. 6. Connect electrical connectors to camshaft position sensor and engine coolant temperature sensor. 7. Remove covering on lower intake manifold and clean surface. 8. Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight. 9. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts (do not tighten.) 10. Following the tightening sequence, tighten intake manifold bolts to 28 Nm (250 in. lbs.) torque. 11. Tighten generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.) torque. 12. Tighten the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.) torque. 13. Connect ground strap and MAP sensor electrical connector. 14. Connect vacuum harness to intake plenum. Connect PCV system hoses. 15. Using a new gasket, connect the EGR tube to the intake manifold plenum. Tighten screws to 22 Nm (200 in. lbs.) torque. 16. Connect electrical connectors to the TPS and idle air control motor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3131 17. Connect vacuum harness to throttle body. 18. Install the direct ignition system (DIS) coils. Tighten fasteners to 12 Nm (105 in. lbs.) torque. 19. Install fuel hose quick connector fitting to chassis tubes. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. Push the fitting onto the chassis tube until it clicks into place. Pull on the fitting to ensure complete insertion. 20. Install throttle cable and speed control cable (if equipped). 21. Install air inlet resonator. 22. Connect negative cable to battery. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. 23. With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations Fuel Return Line: Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations Fuel Supply Line: Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Fuel Tank Sending Unit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Motor Screws 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3148 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3149 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3150 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL MOTOR-PCM OUTPUT The idle air control motor is mounted on the throttle body. The PCM operates the idle air control motor. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load or ambient conditions. The throttle body has an air bypass passage that provides air for the engine at idle (the throttle blade is closed). The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the idle air control motor pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, and various switch operations (brake, park/neutral, air conditioning). Deceleration die out is also prevented by increasing airflow when the throttle is closed quickly after a driving (speed) condition. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3151 Idle Speed/Throttle Actuator - Electronic: Service and Repair When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from idle air control motor. Servicing Idle Air Control Motor 3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the O-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new O-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 2 Nm (17 in. lbs.) torque. 4. Connect electrical connector to idle air control motor. 5. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3155 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3158 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3159 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3160 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3177 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3178 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3181 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 3182 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3187 Power Distribution Center -- Sheet 8w-10-2 The fuel pump relay is located in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3188 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3189 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit contains a 9 amp fuse. The fuse is located in the PDC. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3190 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3191 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3195 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3198 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3199 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3200 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3201 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3202 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3203 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3204 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3205 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3207 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3208 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 Automatic Shut Down (ASD) Relay: Connector Views Power Distribution Center Automatic Shut Down Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3217 Automatic Shut Down (ASD) Relay: Description and Operation Power Distribution Center DESCRIPTION The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and fuses in the PDC. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02 Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3218 Power Distribution Center The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay ASD And Fuel Pump Relay Terminals ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3221 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 3222 Automatic Shut Down (ASD) Relay: Service and Repair The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation DESCRIPTION All vehicles have rollover valve(s) on top of the fuel tank. OPERATION The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover. The rollover valves on the fuel tank are not serviceable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3230 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3231 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3232 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3233 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3234 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Mounting Nuts 25 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3238 Throttle Body: Service Precautions WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3239 Throttle Body: Description and Operation Throttle Body - 2.4L Throttle Body - 3.0L Throttle Body - 3.3/3.8L SYSTEM OPERATION On all engine assemblies the throttle body's are located on the left side of the intake manifold plenum. The throttle body houses the throttle position sensor and the idle air control motor. Air flow through the throttle body is controlled by a cable operated throttle blade located in the base of the throttle body. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3240 Throttle Body: Testing and Inspection 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. PCV Valve 4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6. Air Metering Fitting 6457 a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b. Disconnect the idle purge line from the throttle body nipple. 7. a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector. 8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 10. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum air-flow is set correctly. IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above 1000 Miles = 575-875 RPM 12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3241 b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle purge line. 16. Remove DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3242 Throttle Body: Service and Repair REMOVAL 1. Disconnect negative cable from battery cable. 2. Remove air inlet to throttle body hose clamp. Air Inlet Resonator 3. Remove 2 screws and air inlet resonator. Throttle Cable Attachment To Throttle Body Attachment 4. Remove throttle and the speed control (if equipped) cables from lever and bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3243 Throttle Body Electrical And Vacuum Connections 5. Disconnect electrical connectors from the idle air control motor and throttle position sensor (TPS). 6. Disconnect vacuum hoses from throttle body. 7. Remove throttle body to intake manifold attaching nuts. 8. Remove throttle body and gasket. INSTALLATION 1. Reverse procedure for installation. Tighten throttle body mounting nuts to 25 Nm (225 in. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. REMOVAL 1. Working from the engine compartment, hold the throttle body throttle lever in the wide open position. Throttle Cable Attachment To Throttle Body Attachment 2. Remove the throttle cable from the throttle body cam. Accelerator Pedal And Throttle Cable-Front View 3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft. Accelerator Pedal And Throttle Cable-Rear View Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3247 4. Remove retainer clip from throttle cable and grommet at dash panel. 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. 6. Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simultaneously. Then gently pull the throttle cable from throttle bracket. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install the cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of the pedal shaft. 4. At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and grommet. 5. From the engine compartment, rotate the throttle lever wide open and install the throttle cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screw 2 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3251 Throttle Position Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3252 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3253 Throttle Position Sensor: Description and Operation Throttle Position Sensor THROTTLE POSITION SENSOR (TPS)-PCM INPUT The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions and adjust fuel injector pulse width and ignition timing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3254 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3255 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. Servicing Throttle Position Sensor 4. Lift throttle position sensor off throttle shaft. INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3267 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3268 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3269 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3270 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3271 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3272 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3273 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3277 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3278 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3279 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3280 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3281 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3282 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable = Maximum Resistance #1 = 18.5 K Ohms #2 = 15.5 K Ohms #3 = 20.4 K Ohms #4 = 21.2 K Ohms #5 = 27.7 K Ohms #6 = 26.7 K Ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3286 Ignition Cable: Description and Operation DESCRIPTION The spark plug cables and spark plug boots are made from high temperature silicon materials. The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. They also identify proper heat shield installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The bottom of the spark plug heat shield must make contact with the spark plug hex. The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3287 Ignition Cable: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. Spark Plug Cables # 3 And # 5 REMOVAL 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 3. Remove the cable from the retaining bracket. Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. Spark Plug Cable # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove the cable from the retaining bracket. INSTALLATION 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Ignition Coil: Customer Interest Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3296 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3297 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3298 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3299 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Ignition Coil: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3305 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3306 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3307 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 3308 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Manufacturer = Diamond Electric (Brass Towers) Primary Resistance at 21° C - 27° C (70° F 80° F) = 0.45 to 0.65 ohms Secondary Resistance at 21° C - 27° C (70° F - 80° F) = 7,000 to 15,800 ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3311 Ignition Coil: Mechanical Specifications Ignition Coil Fasteners 12 Nm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3312 Ignition Coil: Locations Ignition Coil Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3313 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3314 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3315 Ignition Coil: Description and Operation WARNING: THE DIRECT IGNITION SYSTEM GENERATES APPROXIMATELY 40,000 VOLTS. PERSONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM. Ignition Coil Pack DESCRIPTION The ignition coil assembly consists of 3 independent coils molded together. The coil assembly is mounted on the intake manifold. Spark plug cables route to each cylinder from the coil. OPERATION The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. The Powertrain Control Module (PCM) determines which of the coils to charge and fire at the correct time. Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5, coil 3 fires cylinders 3 and 6. The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Refer to Auto Shutdown (ASD) Relay-PCM Output, for relay operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Test Ignition Coil: Testing and Inspection Ignition Coil Test Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5, and coil 3 fires cylinders 3 and 6. Each coil tower is labeled with the number of the corresponding cylinder. Ignition Coil Electrical Connector 1. Disconnect the electrical connector from the coil pack. 2. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B+ pin and the pin corresponding to the cylinders in question. Resistance on the primary side of each coil should be 0.53 - 0.65 ohm at 21° to 27° C (70° to 80° F). A coil that has not been allowed to cool off, would result in inaccurate measurement results. Replace the coil if resistance is not within tolerance. Checking Ignition Coil Secondary Resistance 3. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance of the coil between the towers of each individual coil. Secondary resistance should be 10,900 to 14,700 ohms. Replace the coil if resistance is not within tolerance. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Test > Page 3318 Ignition Coil: Testing and Inspection Testing For Spark at Coil WARNING: THE DIRECT IGNITION SYSTEMS GENERATES APPROXIMATELY 40,000 VOLTS. PERSONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM. The coil pack contains independent coils. Each coil must be checked individually. CAUTION: Spark plug wire damage may occur if the spark plug is moved more than 1/4 inch away from the engine ground. CAUTION: Do not leave any one spark plug cable disconnected any longer than 30 seconds or possible heat damage to catalytic converter will occur. CAUTION: Test must be performed at idle and in park only with the parking brake on. Use a new spark plug and spark plug cable for the following test. Testing For Spark 1. Insert a new spark plug into the new spark plug boot. Ground the plug to the engine. Do not hold with your hand. 2. Starting with coil insulator #1, remove it from the DIS coil. 3. Plug the test spark plug cable onto #1 coil tower. Make sure a good connection is made; there should be a click sound. 4. Crank the engine and look for spark across the electrodes of the spark plug. CAUTION: Always install the cable back on the coil tower after testing to avoid damage to the coil and catalytic converter. 5. Repeat the above test for the remaining coils. If there is no spark during all cylinder tests, proceed to the Failure To Start Test. 6. If one or more tests indicate irregular, weak, or no spark, proceed to check coil test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3319 Ignition Coil: Service and Repair REMOVAL Ignition Coil Removal 1. Remove spark plug cables from coil. Always twist the spark plug boots to break the seal with the plug and pull straight back on the boot. 2. Remove ignition coil electrical connector. 3. Remove ignition coil mounting screws. 4. Remove ignition coil. INSTALLATION 1. Reverse the above procedure for installation. Tighten mounting screws to 12 Nm (105 in. lbs.) torque. 2. Transfer spark plug cables to new coil pack. The coil pack towers and cables are numbered with the cylinder identification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3323 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3324 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3325 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3326 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 14 Nm (125 in. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3331 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3332 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3333 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Location DESCRIPTION The camshaft position sensor is mounted in the front of the timing case cover. Camshaft Position Sensor Camshaft Sprocket OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3334 When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Ignition Coil Pack Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder the flat spot and notches identify, they do not indicate TDC position. CAMSHAFT POSITION SENSOR-PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel Injection-Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3335 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3336 Camshaft Position Sensor: Service and Repair REMOVAL Camshaft Position Sensor 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector. Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt. Camshaft Sensor Removal/Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3337 3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3341 Crankshaft Position Sensor Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3342 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3343 Crankshaft Position Sensor: Description and Operation DESCRIPTION Crankshaft Position Sensor Location The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. OPERATION Crankshaft Position Sensor Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3344 it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. CRANKSHAFT POSITION SENSOR-PCM INPUT The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing and presence of misfire. Once crankshaft position has been determined, the PCM begins energizing the injectors in sequence. The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor. The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3345 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3346 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support vehicle. Crankshaft Position Sensor Connector 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the trans axle housing. INSTALLATION Crankshaft Position Sensor And Spacer NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 3356 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 3362 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3373 Ignition Switch Lock Cylinder: Description and Operation DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION Ignition Lock Cylinder Detents The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3374 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3375 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3379 Knock Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3380 Knock Sensor: Description and Operation Knock Sensor KNOCK SENSOR-PCM INPUT The knock sensor is only on these engines. The knock sensor threads into the side of the cylinder block in front of the starter. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3381 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3382 Knock Sensor: Service and Repair Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3386 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3387 Spark Plug: Description and Operation SPARK PLUGS RESISTER DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Setting Spark Plug Electrode Gap Refer to the Specifications for gap and type of spark plug. SPARK PLUGS PLATINUM DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule. All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads The spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions per schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both electrode ends as shown. Extreme care must be used to prevent spark plug cross threading, mis-gaping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3388 Spark Plug: Testing and Inspection Spark Plug Condition Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Normal Operating Conditions Normal Operation And Cold (Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and then reinstalled. CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones. Oil Or Ash Encrusted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3389 Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Electrode Gap Bridging Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Scavenger Deposits Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3390 Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. Spark plugs with chipped electrode insulators must be replaced. Preignition Damage Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3391 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3392 Spark Plug: Service and Repair WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. Spark Plug Boot/Heat Shield Orientation Use extreme care when removing and installing the spark plug cables. The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine. If it is not installed correctly engine misfire would occur. Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly Spark Plug # 3 AND # 5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator]ator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. Spark Plug # 1 REMOVAL 1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations A604 (41TE) 4 Speed Transaxle Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications Control Module: Specifications Sixty-Way Connector 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications > Page 3404 Transmission Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3426 Control Module: Description and Operation AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT The electronic automatic transaxle control module and the PCM supply information to each other through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the information when adjusting the fuel and ignition strategy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3427 Control Module: Service and Repair OVERVIEW Do not interchange Transmission Control Modules with previous year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. REMOVAL Fig. 27 1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then disconnect the 60 way connector on Transmission Control Module. Fig. 28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3428 Fig. 29 2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28 and 29). INSTALLATION 1. To install, reverse removal procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3432 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3433 Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3434 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY The transmission control relay is located in the Power Distribution Center (PDC) on the left side of the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in mode. After a controller reset (ignition key turned to the run position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Autostick/Overdrive Off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3440 Autostick/Overdrive Switch Connector Pin Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3444 Transmission Mode Switch: Diagrams For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3449 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3450 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3451 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3452 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3453 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3454 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3455 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 3464 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3470 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3471 Transmission Speed Sensor: Specifications Speed Sensor Input 20 ft.lb Output 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3472 Input Speed Sensor/Output Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3475 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor Transmission Speed Sensor: Service and Repair Input Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 25 The input speed sensor is located to the left of the manual shift lever (Fig. 25). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 3478 Transmission Speed Sensor: Service and Repair Output Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 26 The output speed sensor is located to the right of the manual shift lever (Fig. 26). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. PROM - Programmable Read Only Memory: Customer Interest PCM - A/C System Blows Warm Air Intermittently. NUMBER: 24-10-99 Rev. A GROUP: Heating And A/C DATE: Aug. 20, 1999 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 24-10-99 DATED MAY 28, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND EXCLUDES CERTAIN ENGINE APPLICATIONS. SUBJECT: A/C System Blows Warm Air Intermittently OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). MODELS: 1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market) **NOTE: THIS INFORMATION APPLIES TO ALL APPLICATIONS EXCEPT NS MODELS WITH A 3.0L ENGINE AND GS MODELS WITH A 2.4L/4 SPEED EATX COMBINATION.** SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent condition where the A/C system blows warm air after the A/C system had been working properly. This could occur when the vehicle is travelling above 40 mph and the engine is NOT in an overheat condition. The discharge vents may suddenly blow warm air continuously until the A/C select button is re-selected or the vehicle is re-started. Once the A/C select button is re-selected or vehicle is re-started, the A/C system will function normally again. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present and the customer has described the above symptoms, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2034 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON" Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. > Page 3487 3. Using the arrow keys, select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Using the arrow keys, select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R) AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. > Page 3488 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3493 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3494 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3495 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory Technical Service Bulletin # 18-11-00 Date: 000728 A/T - DTC P1714 Stored in Memory NUMBER: 18-11-00 GROUP: Vehicle Performance DATE: July 28, 2000 SUBJECT: Low Voltage Clutch Protection - Added DTC - P1714 Low Battery Voltage OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software. MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS)Chrysler Voyager (European Market) 1999 (JA)Cirrus/Stratus/Breeze 1999 (JX)Sebring Convertible 1999 (LH)Concorde/Intrepid/LHS/300M 1999 (NS)Town & Country/Caravan/Voyager 1999 (PR)Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE AUTOMATIC TRANSAXLE BUILT PRIOR TO: DISCUSSION: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3501 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3502 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3503 Operation of vehicles with low battery voltage may result in the transaxle overdrive clutch becoming distressed. Conditions such as an inoperative charging system or excess voltage drop to the TCM circuits may be causes for low voltage. The software released by this Technical Service Bulletin provides protection to the overdrive clutch and adds a new DTC - P1714 LOW BATTERY VOLTAGE for these models. Diagnostic procedures relating to P1714 are included for your reference. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3504 AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2063 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-51-90 Module Reprogram 0.5 Hrs. FAILURE CODE: FM - Flash Module Symptom: P1714-LOW BATTERY VOLTAGE When Monitored and Set Condition: P1714-LOW BATTERY VOLTAGE When Monitored: With the engine running and the TCM has closed the Transmission Control Relay. Set Condition: If battery voltage at TCM Transmission Control Relay Output Sense circuit is less than 10.0 volts for 15 seconds. *P-1714 generally indicates a gradually falling battery voltage or resistive connections to the TCM. Possible Causes RELATED CHARGING SYSTEM DTCS INTERMITTENT WIRING AND CONNECTORS FUSED B+ CIRCUIT OPEN OR HIGH RESISTANCE GROUND CIRCUIT OPEN OR HIGH RESISTANCE TRANS CONTROL RELAY OUTPUT TO TCM OPEN OR HIGH RESISTANCE TRANSMISSION CONTROL RELAY OPEN OR HIGH RESISTANCE TCM - LOW BATTERY VOLTAGE Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3505 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - A/C System Blows Warm Air Intermittently. NUMBER: 24-10-99 Rev. A GROUP: Heating And A/C DATE: Aug. 20, 1999 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 24-10-99 DATED MAY 28, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND EXCLUDES CERTAIN ENGINE APPLICATIONS. SUBJECT: A/C System Blows Warm Air Intermittently OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). MODELS: 1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market) **NOTE: THIS INFORMATION APPLIES TO ALL APPLICATIONS EXCEPT NS MODELS WITH A 3.0L ENGINE AND GS MODELS WITH A 2.4L/4 SPEED EATX COMBINATION.** SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent condition where the A/C system blows warm air after the A/C system had been working properly. This could occur when the vehicle is travelling above 40 mph and the engine is NOT in an overheat condition. The discharge vents may suddenly blow warm air continuously until the A/C select button is re-selected or the vehicle is re-started. Once the A/C select button is re-selected or vehicle is re-started, the A/C system will function normally again. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present and the customer has described the above symptoms, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2034 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON" Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. > Page 3510 3. Using the arrow keys, select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Using the arrow keys, select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R) AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. > Page 3511 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3516 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3517 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3518 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory Technical Service Bulletin # 18-11-00 Date: 000728 A/T - DTC P1714 Stored in Memory NUMBER: 18-11-00 GROUP: Vehicle Performance DATE: July 28, 2000 SUBJECT: Low Voltage Clutch Protection - Added DTC - P1714 Low Battery Voltage OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software. MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS)Chrysler Voyager (European Market) 1999 (JA)Cirrus/Stratus/Breeze 1999 (JX)Sebring Convertible 1999 (LH)Concorde/Intrepid/LHS/300M 1999 (NS)Town & Country/Caravan/Voyager 1999 (PR)Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE AUTOMATIC TRANSAXLE BUILT PRIOR TO: DISCUSSION: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3524 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3525 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3526 Operation of vehicles with low battery voltage may result in the transaxle overdrive clutch becoming distressed. Conditions such as an inoperative charging system or excess voltage drop to the TCM circuits may be causes for low voltage. The software released by this Technical Service Bulletin provides protection to the overdrive clutch and adds a new DTC - P1714 LOW BATTERY VOLTAGE for these models. Diagnostic procedures relating to P1714 are included for your reference. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3527 AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2063 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-51-90 Module Reprogram 0.5 Hrs. FAILURE CODE: FM - Flash Module Symptom: P1714-LOW BATTERY VOLTAGE When Monitored and Set Condition: P1714-LOW BATTERY VOLTAGE When Monitored: With the engine running and the TCM has closed the Transmission Control Relay. Set Condition: If battery voltage at TCM Transmission Control Relay Output Sense circuit is less than 10.0 volts for 15 seconds. *P-1714 generally indicates a gradually falling battery voltage or resistive connections to the TCM. Possible Causes RELATED CHARGING SYSTEM DTCS INTERMITTENT WIRING AND CONNECTORS FUSED B+ CIRCUIT OPEN OR HIGH RESISTANCE GROUND CIRCUIT OPEN OR HIGH RESISTANCE TRANS CONTROL RELAY OUTPUT TO TCM OPEN OR HIGH RESISTANCE TRANSMISSION CONTROL RELAY OPEN OR HIGH RESISTANCE TCM - LOW BATTERY VOLTAGE Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3528 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations A604 (41TE) 4 Speed Transaxle Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations A604 (41TE) 4 Speed Transaxle Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 21-15-99 > Oct > 99 > A/T - Case Porosity/Fluid Seepage Case: Customer Interest A/T - Case Porosity/Fluid Seepage NUMBER: 21-15-99 GROUP: Transmission DATE: Oct. 1, 1999 SUBJECT: Transaxle Seepage Mis-Diagnosis - Case Porosity OVERVIEW: This bulletin involves properly identifying the seepage location (porosity) and if applicable, using a peening process to seal the porous area of the transaxle case. MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS) Chrysler Voyager (International Market) 1999 (JA) Cirrus/Stratus/Breeze 1999 (JX) Sebring Convertible 1999 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit seepage from the transaxle case. This seepage may be due to case porosity in the cooler boss area and can be mis-diagnosed as leakage from the pan, or input speed sensor. Transaxles that may exhibit this condition have a web of metal attaching the cooler bosses and the input speed sensor boss (Figure 1). This web forms a circular pocket in that area. DIAGNOSIS: Start the vehicle and warm the transaxle fluid to 93° C (200° F). Clean the transaxle pan and the area around the input speed sensor. Pay particular attention to cleaning the boss area between the cooler lines, above the input speed sensor (Figure 1). With a helper in the vehicle, set the parking brake, place the transaxle in reverse, apply the service brake and raise the RPM to approximately 1100 RPM for at least 3 minutes. Inspect the cooler line boss area just above the input speed sensor (Figure 1). If seepage is noted from the pocket formed by the web of metal, the following repair procedure can be used. If case seepage is not noted in this area, further diagnosis will be required. EQUIPMENT REQUIRED: 1 NPN Air Hammer 1 PH59 Snap-On Tapered Punch Or Equivalent Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 21-15-99 > Oct > 99 > A/T - Case Porosity/Fluid Seepage > Page 3548 REPAIR PROCEDURE: 1. Remove components for clear access to the transaxle as follows: FJ Models - Air intake hose (throttle body to airbox), air box cover & filter, and left cooling fan module. JA/JX Models - Transaxle Control Module (TCM), TCM bracket and solenoid pack electrical connector. NS/GS Models - Air intake hose at throttle body & resonator, airbox cover & filter, and solenoid pack electrical connector. 2. Using a suitable air hammer and blunt punch attachment (Snap-On PH59 or equivalent), insert the punch into the pocket formed by the web of metal (Figure 1). 3. Operate the air hammer for 15 to 20 seconds while moving the punch in a circular motion within the pocket. Start in the center of the pocket and work outwards in a clockwise or counter clockwise pattern. 4. Repeat step 3 and then reassemble the vehicle. NOTE: ONLY OPERATE THE AIR HAMMER IN 15 TO 20 SECOND INTERVALS. 5. Re-test the transaxle for leaks by performing the procedure listed in the diagnosis section. 6. If the leak is repaired, return the vehicle to the customer. NOTE: BE SURE TO CLEAN ANY REMAINING TRANSAXLE FLUID FROM THE VEHICLE TO PREVENT CONTINUED DRIPPING ON THE GROUND. 7. If the area continues to leak, the transaxle will require replacement. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-00-20-92 0.7 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 21-15-99 > Oct > 99 > A/T - Case Porosity/Fluid Seepage Case: All Technical Service Bulletins A/T - Case Porosity/Fluid Seepage NUMBER: 21-15-99 GROUP: Transmission DATE: Oct. 1, 1999 SUBJECT: Transaxle Seepage Mis-Diagnosis - Case Porosity OVERVIEW: This bulletin involves properly identifying the seepage location (porosity) and if applicable, using a peening process to seal the porous area of the transaxle case. MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS) Chrysler Voyager (International Market) 1999 (JA) Cirrus/Stratus/Breeze 1999 (JX) Sebring Convertible 1999 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit seepage from the transaxle case. This seepage may be due to case porosity in the cooler boss area and can be mis-diagnosed as leakage from the pan, or input speed sensor. Transaxles that may exhibit this condition have a web of metal attaching the cooler bosses and the input speed sensor boss (Figure 1). This web forms a circular pocket in that area. DIAGNOSIS: Start the vehicle and warm the transaxle fluid to 93° C (200° F). Clean the transaxle pan and the area around the input speed sensor. Pay particular attention to cleaning the boss area between the cooler lines, above the input speed sensor (Figure 1). With a helper in the vehicle, set the parking brake, place the transaxle in reverse, apply the service brake and raise the RPM to approximately 1100 RPM for at least 3 minutes. Inspect the cooler line boss area just above the input speed sensor (Figure 1). If seepage is noted from the pocket formed by the web of metal, the following repair procedure can be used. If case seepage is not noted in this area, further diagnosis will be required. EQUIPMENT REQUIRED: 1 NPN Air Hammer 1 PH59 Snap-On Tapered Punch Or Equivalent Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 21-15-99 > Oct > 99 > A/T - Case Porosity/Fluid Seepage > Page 3554 REPAIR PROCEDURE: 1. Remove components for clear access to the transaxle as follows: FJ Models - Air intake hose (throttle body to airbox), air box cover & filter, and left cooling fan module. JA/JX Models - Transaxle Control Module (TCM), TCM bracket and solenoid pack electrical connector. NS/GS Models - Air intake hose at throttle body & resonator, airbox cover & filter, and solenoid pack electrical connector. 2. Using a suitable air hammer and blunt punch attachment (Snap-On PH59 or equivalent), insert the punch into the pocket formed by the web of metal (Figure 1). 3. Operate the air hammer for 15 to 20 seconds while moving the punch in a circular motion within the pocket. Start in the center of the pocket and work outwards in a clockwise or counter clockwise pattern. 4. Repeat step 3 and then reassemble the vehicle. NOTE: ONLY OPERATE THE AIR HAMMER IN 15 TO 20 SECOND INTERVALS. 5. Re-test the transaxle for leaks by performing the procedure listed in the diagnosis section. 6. If the leak is repaired, return the vehicle to the customer. NOTE: BE SURE TO CLEAN ANY REMAINING TRANSAXLE FLUID FROM THE VEHICLE TO PREVENT CONTINUED DRIPPING ON THE GROUND. 7. If the area continues to leak, the transaxle will require replacement. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-00-20-92 0.7 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 3555 Case: Specifications Rear End Cover 175 in.lb Transfer Plate To Case 105 in.lb Vent Assembly 105 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch Clutch: Specifications Low/Rev Clutch Select Reaction Plate 0.035 - 0.042 in Clutch Retainer 45 in. lbs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch > Page 3560 Clutch: Specifications Overdrive Clutch No Selection 0.053 - 0.125 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch > Page 3561 Clutch: Specifications Reverse Clutch Select Snap Ring 0.030 - 0.049 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch > Page 3562 Clutch: Specifications Two/Four Clutch No Selection 0.030 - 0.104 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch > Page 3563 Clutch: Specifications Underdrive Clutch Select Pressure Plate 0.036 - 0.058 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Specifications Control Module: Specifications Sixty-Way Connector 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Specifications > Page 3567 Transmission Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3586 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3587 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3588 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Page 3589 Control Module: Description and Operation AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT The electronic automatic transaxle control module and the PCM supply information to each other through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the information when adjusting the fuel and ignition strategy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Page 3590 Control Module: Service and Repair OVERVIEW Do not interchange Transmission Control Modules with previous year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. REMOVAL Fig. 27 1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then disconnect the 60 way connector on Transmission Control Module. Fig. 28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Page 3591 Fig. 29 2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28 and 29). INSTALLATION 1. To install, reverse removal procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Case, A/T > Component Information > Specifications Differential Case: Specifications Differential Cover 165 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension Housing 21 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3603 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3604 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 31TH .................................................................................................................................................... ............................................................. 8.0L (8.5 Qt) 41TE ................................................................. ................................................................................................................................................ 8.6L (9.1 Qt) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3607 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3608 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check NOTE: The transmission and differential utilize the same fluid sump, which require Automatic Transmission Fluid (ATF+4/Type 9602). NOTE: The transmission fluid level should be inspected at least every six months. FLUID LEVEL CHECK The transmission sump has a dipstick to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fig. 7 The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C or 180°F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator (Fig. 7). The fluid level will be approximately one-quarter inch above the lower hole of the dipstick at 70°F fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRBIII scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. 5. Compare the fluid temperature value with the chart. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3611 TRANSMISSION FLUID TEMPERATURE CHART 6. Adjust transmission fluid level shown on the dipstick according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3612 Fluid - A/T: Service and Repair Fluid and Filter Service NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. Fig. 8 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. TRANSMISSION FLUID TEMPERATURE CHART Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3613 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening ALTERNATIVE SERVICE METHODS (FLUID ONLY) TRANSAXLE FLUID EXCHANGER METHOD CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not recommended. 1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive the vehicle until it reaches full operating temperature. 2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the vehicle following the manufacturers instructions. Perform the exchange procedure following the instructions provided with the machine. 5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to proper level with MOPAR ATF+4 Type 9602. Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure. NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line torque specification is 2 Nm (18 inch lbs.). DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. Fig. 8 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. TRANSMISSION FLUID TEMPERATURE CHART Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 3617 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening ALTERNATIVE SERVICE METHODS (FLUID ONLY) TRANSAXLE FLUID EXCHANGER METHOD CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not recommended. 1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive the vehicle until it reaches full operating temperature. 2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the vehicle following the manufacturers instructions. Perform the exchange procedure following the instructions provided with the machine. 5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to proper level with MOPAR ATF+4 Type 9602. Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure. NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line torque specification is 2 Nm (18 inch lbs.). DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick. 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T Oil Cooler Line Hose Clamp - Revised Fluid Line/Hose: Technical Service Bulletins A/T Oil Cooler Line Hose Clamp - Revised NUMBER: 07-006-01 GROUP: Cooling DATE: Nov. 11, 2001 SUBJECT: Transmission Oil Cooler Line Hose Clamp Service OVERVIEW: This bulletin provides revised transmission oil cooler hose clamp information. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) DISCUSSION: A revised transmission oil cooler hose clamp is now available and should be used any time it is necessary to separate oil cooler hose connections. Tighten the clamp(s) to 3.2 Nm (28 in. lbs.). Transmission oil cooler hoses should be replaced only it they are damaged. NOTE: WEATHERED SURFACE APPEARANCE ON TRANSMISSION OIL COOLER HOSES IS A NORMAL CONDITION AND WILL NOT IMPAIR THEIR ABILITY TO SEAL. PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 3622 Fluid Line/Hose: Specifications Oil Cooler Line Fittings 105 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications TORQUE SPECIFICATIONS Bolt, Oil Pan-to-Case ........................................................................................................................... ..................................................... 19 Nm (14 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Dimensional Fluid Pump: Specifications Oil Pump Outer Gear To Pocket 0.0018 - 0.0056 in Outer Gear Side Clearance 0.0008 - 0.0018 in Inner Gear Side Clearance 0.0008 - 0.0018 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Dimensional > Page 3630 Fluid Pump: Specifications Oil Pump To Case Bolts 20 ft.lb Reaction Shaft Bolts 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications Input Shaft: Specifications Input Shaft End Play 0.005 - 0.025 in Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications Output Shaft: Specifications Output Gear Bolt 200 ft.lb Stirrup Retainer 17 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Autostick/Overdrive Off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3640 Autostick/Overdrive Switch Connector Pin Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications Control Module: Specifications Sixty-Way Connector 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications > Page 3645 Transmission Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3648 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3649 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3650 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3651 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3652 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3653 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3667 Control Module: Description and Operation AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT The electronic automatic transaxle control module and the PCM supply information to each other through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the information when adjusting the fuel and ignition strategy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3668 Control Module: Service and Repair OVERVIEW Do not interchange Transmission Control Modules with previous year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. REMOVAL Fig. 27 1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then disconnect the 60 way connector on Transmission Control Module. Fig. 28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3669 Fig. 29 2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28 and 29). INSTALLATION 1. To install, reverse removal procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3673 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3674 Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3675 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY The transmission control relay is located in the Power Distribution Center (PDC) on the left side of the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in mode. After a controller reset (ignition key turned to the run position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation > Page 3680 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 3681 Seals and Gaskets: Service and Repair REMOVAL Fig. 48 INSTALLATION Fig. 49 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Autostick/Overdrive Off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3686 Autostick/Overdrive Switch Connector Pin Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3690 Transmission Mode Switch: Diagrams For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3695 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3696 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3697 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3698 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3699 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3700 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3701 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3710 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3716 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3717 Transmission Speed Sensor: Specifications Speed Sensor Input 20 ft.lb Output 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3718 Input Speed Sensor/Output Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3721 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor Transmission Speed Sensor: Service and Repair Input Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 25 The input speed sensor is located to the left of the manual shift lever (Fig. 25). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 3724 Transmission Speed Sensor: Service and Repair Output Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 26 The output speed sensor is located to the right of the manual shift lever (Fig. 26). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations A604 (41TE) 4 Speed Transaxle Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair REMOVAL Fig. 14 1. Remove shift cable from lever (Fig. 14). Fig. 15 2. Loosen the lever mounting bolt (Fig. 15). Do not remove bolt (not necessary). 3. Pull up on lever and remove. INSTALLATION 1. For installation, reverse removal procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Lift and rotate the gearshift hand lever into the park (P) gate position and remove the ignition key. This confirms the shift lever is in the gated park (P) position. After confirming the park gate position' turn the ignition switch. If the starter will operate, the park gate position is correct. Move the shift lever into the neutral (N) position. If the starter will operate in this position, the linkage is properly adjusted. If the starter fails to operate in either position, linkage adjustment is required. 1. Park the vehicle on level ground and set the parking brake. 2. Place the gearshift lever in park (P) gate position and remove key. Fig. 13 3. Loosen the cable adjustment screw at the transaxle operating lever (Fig. 13). 4. Pull the transaxle operating lever fully forward to the park detent position. 5. Release the park brake, then rock the vehicle to assure it is in park lock. Reset the park brake. 6. Tighten the cable adjustment screw to 8 Nm (70 inch lbs.). Gearshift cable should now be properly adjusted. 7. Check adjustment by using the preceding procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3735 Shift Cable: Service and Repair REMOVAL Fig. 9 1. Remove cable eyelet attachment from transaxle operating lever pin (Fig. 9). Fig. 10 Fig. 11 2. Using pliers, squeeze ears of cable conduit attachment at mounting bracket (Fig. 10) and push through hole to remove (Fig. 11). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3736 Fig. 12 3. Remove the under instrument panel silencer (Fig. 12). 4. At the steering column attachment, remove the cable eyelet attachment from the shift lever pin. 5. Using pliers, squeeze ears of cable attachment at mounting bracket then push through hole to remove. 6. Unseat the dash grommet and remove the cable from the vehicle. INSTALLATION 1. Install cable into steering column attachment bracket. Verify conduit ears are fully engaged. Verify cable does not interfere with brake pedal actuation. 2. Attach cable eyelet fitting onto shift lever pin. 3. Insert transaxle end of cable through dash panel hole and fully seat grommet 4. Install instrument panel silencer. Verify gearshift cable is routed through the slot in the silencer. CAUTION: Failure to route the cable properly at the silencer may cause brake pedal interference. 5. Attach transaxle end of cable to the mounting bracket on the transaxle. Assure the conduit attachment ears are fully seated. 6. Attach cable eyelet fitting onto the transaxle operating lever. 7. Complete adjustment using the gearshift cable adjustment procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3740 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3741 Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3742 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY The transmission control relay is located in the Power Distribution Center (PDC) on the left side of the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in mode. After a controller reset (ignition key turned to the run position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation Transmission Cooler: Description and Operation Auxiliary Transmission Oil Cooler The primary transmission oil cooler is an internal oil-to-coolant type, mounted in the radiator left tank. Also, an auxiliary oil-to-air type cooler is mounted in front of the A/C condenser. Use only approved transmission oil cooler hose. Since these are molded to fit space available, molded hoses are recommended. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Cooler Flow Check Transmission Cooler: Service and Repair Cooler Flow Check After the new or repaired transmission has been installed, fill to the proper level with MOPAR ATF+4 (Type 9602) automatic transmission fluid. The volume should be checked using the following procedure: 1. Disconnect the From cooler line at the transmission and place a collecting container under the disconnected line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed 1 quart or internal damage to the transmission may occur. 2. Run the engine at curb idle speed, with the shift selector in neutral. 3. If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF, disconnect the To Cooler line at the transaxle. 4. Refill the transaxle to proper level and recheck pump volume. 5. If flow is found to be within acceptable limits, replace the cooler. Then fill transmission to the proper level, using MOPAR ATF+ 3 (Type 9602) automatic transmission fluid. 6. If fluid flow is still found to be inadequate, check the line pressure using the Transaxle Hydraulic Pressure Test procedure. 7. Check the cooler for debris on the external surfaces. Clean as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Cooler Flow Check > Page 3748 Transmission Cooler: Service and Repair Flushing Coolers and Tubes When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler bypass valve in the transaxle must be replaced also. The torque converter must also be replaced with an exchange unit. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transaxle. The recommended procedure for flushing the transaxle cooler is to use Tool 6906A Cooler Flusher. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. - KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. - KEEP THE AREA WELL VENTILATED. - DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. COOLER FLUSH USING TOOL 6906A 1. Remove cover plate filler plug on Tool 6906A. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of MOPAR ATF+4 Type 9602 automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 3752 Transmission Mode Switch: Diagrams For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Refer to Engine; Drive Belts, Mounts, Brackets and Accessories; Engine Mount; Service and Repair for procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3760 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3761 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3762 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3763 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3764 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3765 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3766 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Pressure Port Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3778 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3784 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3785 Transmission Speed Sensor: Specifications Speed Sensor Input 20 ft.lb Output 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3786 Input Speed Sensor/Output Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3789 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor Transmission Speed Sensor: Service and Repair Input Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 25 The input speed sensor is located to the left of the manual shift lever (Fig. 25). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 3792 Transmission Speed Sensor: Service and Repair Output Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 26 The output speed sensor is located to the right of the manual shift lever (Fig. 26). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Valve Body To Case Bolts ................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Valve Body Bolts .............................................. ...................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3796 A604 (41TE) 4 Speed Transaxle Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3797 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation REMOVAL NOTE: To ease removal of the valve body, turn the manual valve lever fully clockwise. Refer to figures 30 through 36 for procedures. Fig. 30 Fig. 31 Fig. 32 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3800 Fig. 33 Fig. 34 Fig. 35 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3801 Fig. 36 INSTALLATION To install valve body, reverse removal procedure CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise. Guide park rod rollers into guide bracket, while shifting manual lever assembly out of the installation position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3802 Valve Body: Service and Repair Disassembly and Assembly Refer to Figures 50 through 61 for procedure. Fig. 50 Fig. 51 Fig. 52 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3803 Fig. 53 Fig. 54 Fig. 55 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3804 Fig. 56 Fig. 57 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3805 Fig. 58 Fig. 59 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3806 Fig. 60 Fig. 61 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3807 Valve Body: Service and Repair Cleaning and Inspection CLEANING VALVE BODY Prior to removing any transaxle parts, plug all openings and clean unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs. NOTE: Tag all springs, as they are removed, for reassembly identification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3808 Valve Body: Service and Repair Solenoid Assembly Replacement REMOVAL Input Speed Sensor Removed Remove Sound Cover Remove Attaching Screws Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3809 Remove Solenoid Assembly INSTALLATION To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Capacity ............................................................................................................................................... ......................................................... 1.9L (4.0 Pints) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3815 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 3816 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation Axle Shaft: Description and Operation Vehicles equipped with either an automatic or manual transmission uses an unequal length driveshaft system. Vehicles equipped with automatic transaxles use a solid short interconnecting shaft on the left side. The right side of the vehicle uses a longer solid interconnecting shaft. The left driveshaft uses a tuned rubber damper weight, which is a double clamp style damper. When replacing the left driveshaft, be sure the replacement driveshaft has the same damper weight as the original. Both driveshaft assemblies use the same type of inner and outer joints. The inner joint of both driveshaft assemblies is a tripod joint, and the outer joint of both driveshaft assemblies is a Rzeppa joint. Both tripod joints and Rzeppa joints are true Constant Velocity (C/V) joint assemblies. The inner tripod joint allows for the changes in driveshaft length through the jounce and rebound travel of the front suspension. On vehicles equipped with ABS brakes, the outer C/V joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both driveshafts is splined into the transaxle side gears. The inner tripod joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of the tripod joint. The outer C/V joint has a stub shaft that is splined into the wheel hub and retained by a hub nut using a nut lock and cotter pin, hub nut retention system. NOTE: This vehicle does not use a rubber lip bearing seal as on past front wheel drive cars, to prevent contamination of the front wheel bearing. On these vehicles, the face of the outer CV joint has a metal bearing shield which is pressed onto the end of the outer CV joint housing. This design deters direct water splash on bearing seal while allowing any water that gets in, to run out the bottom of the bearing shield. It is important though to thoroughly clean the outer CV joint and the wheel bearing area in the steering knuckle before it is assembled after servicing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 3822 Axle Shaft: Testing and Inspection VEHICLE INSPECTION 1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. 2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: 1. Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. 2. Noise may also be caused by another component of the vehicle coming in contact with the driveshafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or outer joint of the driveshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the driveshaft assembly. 3. A damaged or worn driveshaft C/V joint. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: 1. A worn or damaged driveshaft inner tripod joint. 2. A sticking tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. See Wheel Alignment specifications. VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: 1. Foreign material (mud, etc.) packed on the backside of the wheel(s). 2. Out of balance front tires or wheels. 3. Improper tire and/or wheel runout. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation Axle Shaft: Service and Repair Removal and Installation REMOVAL CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.). This will ensure that the hub bearing cannot loosen. Fig. 1 1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle. Fig. 2 2. Loosen (but do not remove) stub axle to hub/bearing retaining nut. Loosen hub nut while vehicle is on the floor with the brakes applied. The front hub and driveshaft are splined together and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Remove front tire and wheel assembly from the hub. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3825 Fig. 3 5. Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts. Fig. 4 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. Fig. 5 7. Support brake caliper/adapter assembly using a wire hook. Do not support assembly by the brake flex hose. 8. Remove braking disc from front hub. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3826 Fig. 6 9. Remove nut attaching outer tie rod end to steering knuckle. Remove nut from tie rod end by holding tie rod end stud with a 11/32 socket and loosen and remove nut. Fig. 7 10. Remove the tie rod end stud from steering knuckle arm, using remover, Special Tool MB-990635. Fig. 8 11. If equipped with antilock brakes, remove the speed sensor cable routing bracket from the steering knuckle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3827 Fig. 9 12. Remove cotter pin and castle nut from stud of lower ball joint at the steering knuckle. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 13. Fig. 10 13. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike steering knuckle boss until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. NOTE: Care must be taken not to separate the inner ON joint during this operation. Do not allow driveshaft to hang by inner ON joint. Driveshaft must be supported. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3828 Fig. 11 14. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. CAUTION: When inserting pry bar between inner tripod joint and transaxle case, care must be used to ensure no damage occurs to oil seal in transaxle case. Fig. 12 15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and transaxle case. Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3829 Fig. 13 16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.). This will ensure that the hub bearing cannot loosen. INSTALLATION 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand. 3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle. Fig. 14 5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly. Fig. 15 6. Slide driveshaft back into front hub. Then install steering knuckle onto the lower control arm ball joint stud. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3830 Fig. 16 7. Install the steering knuckle to ball joint stud castle nut. Tighten the castle nut to 95 Nm (70 ft. lbs.). Fig. 17 8. If equipped with antilock brakes, install the speed sensor cable on the steering knuckle and securely tighten bolt. Fig. 18 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3831 Fig. 19 9. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary , tighten tie rod end to steering knuckle nut. Using a crowfoot and 11/32 socket, tighten the nut to 61 Nm (45 ft. lbs.). 10. Install braking disc back on hub and bearing assembly. Fig. 20 11. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. Fig. 21 12. Install caliper assembly to steering knuckle guide pin bolts. Tighten caliper assembly bolts to 31 Nm (23 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3832 Fig. 22 13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto threads of stub axle and tighten nut. Fig. 23 14. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 244 Nm (180 ft. lbs.). Fig. 24 15. Install the spring washer, hub nut lock, and new cotter pin on end of stub axle. Wrap cotter pin prongs tightly around the hub nut lock. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3833 Fig. 25 16. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in the correct sequence. Tighten lug nuts to 135 Nm (100 ft. lbs.). 17. Lower vehicle. 18. Check for correct fluid level in transaxle assembly. Refer to Transmission and Drivetrain for the correct fluid level checking procedure for the type of transaxle being checked. 19. Set front toe on vehicle to required specification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3834 Axle Shaft: Service and Repair Disassembly and Assembly CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the interconnecting shaft where the cross is installed. This twist causes a interference fit between the interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting shaft. This design eliminates the clearance between the cross and the interconnecting shaft resulting in quieter operation of the driveshaft assembly. This design though eliminated the capability of removing the outer C/V joint from the interconnecting shaft. For this reason the driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft and vibration damper) in the event of a outer C/V joint boot failure. NOTE: The only service which is to be performed on the driveshaft assemblies is the replacement of the driveshaft seal boots on the inner tripod joints. If any failure of internal driveshaft components is diagnosed during a vehicle road test or disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly. CAUTION: Lubricant requirements and quantities are different for inner joints than for outer joints. Use only the recommended lubricants in the required quantities when servicing driveshaft assemblies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair Constant Velocity Joint: Service and Repair OVERVIEW The front hub/bearing shield on the outer C/V joint is a serviceable component of the outer C/V. If it is damaged in use on a vehicle or during servicing of a driveshaft it can be replaced using the following procedure. To remove the bearing shield from the outer C/V joint, the driveshaft assemblies must be removed from the vehicle. BEARING SHIELD REMOVAL FROM OUTER CV JOINT 1. Clamp driveshaft in a vise by the interconnecting shaft. Fig. 49 2. Using a drift tap around the entire edge of the bearing shield until it is removed from. BEARING SHIELD INSTALLATION ON OUTER C/V JOINT 1. Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint. Fig. 50 2. Position installer, Special Tool, C-4698-2 and handle, Special Tool, C-4698-1 on face of bearing shield. CAUTION: If bearing shield is not installed flush against the face of the outer C/V joint, interference with steering knuckle will occur when driveshaft is installed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Page 3838 Fig. 51 3. Using a hammer, drive the bearing shield on the outer C/V joint until it is flush against the front of the outer C/V joint. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > CV Boot - Grease Seepage Explanation Constant Velocity Joint Boot: Technical Service Bulletins CV Boot - Grease Seepage Explanation NO: 03-06-98 GROUP: Differential & Drive Line DATE: Oct. 2, 1998 SUBJECT: CV Boot Grease Seepage MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) DISCUSSION: The right side half shaft inner CV joint boot on subject vehicles is made of a special high temperature resistant material that can show heavy grease seepage - enough to form droplets on the boot convolutes. Although the seepage is unsightly and will stop eventually, it does not affect function or durability. No replacement of the half shaft or boot is necessary for this condition. The boot should be wiped clean as necessary. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Constant Velocity Joint Boot: Service and Repair Inner Tripod Joint Sealing Boot REMOVAL To remove sealing boots from driveshafts, the driveshaft assemblies must be removed from the vehicle. The inner tripod joints use no internal retention in the tripod housing to keep the spider assembly in the housing. Therefore, do not pull on the interconnecting shaft to disengage tripod housing from transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing boots. 1. Remove the driveshaft requiring boot replacement from the vehicle. 2. Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and discard. Remove small clamp which retains inner tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the tripod joint housing from the spider assembly' hold the bearings in place on the spider bunions to prevent the bearings from falling away. Fig. 26 3. Slide the tripod joint housing off the spider assembly and the interconnecting shaft. Fig. 27 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3845 Fig. 28 4. Remove snap ring which retains spider assembly to interconnecting shaft. Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift. Do not hit the outer tripod bearings in an attempt to remove spider from interconnecting. shaft. 5. Slide sealing boot off interconnecting shaft. 6. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable. INSTALLATION NOTE: The inner tripod joint sealing boots are made from two different types of material. High temperature applications use silicone rubber where as standard temperature applications use hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot which was removed. Fig. 29 1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the replacement inner tripod joint sealing boot onto the interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3846 Fig. 30 Fig. 31 2. Install spider assembly onto interconnecting shaft. Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift. Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. Fig. 32 3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of interconnecting shaft. Be sure the snap ring is fully seated into Groove on interconnecting shaft. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3847 4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. Fig. 33 5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft. 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot. Fig. 34 Fig. 35 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3848 7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. CAUTION: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability can be adversely affected. CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used. Fig. 36 9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly. When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing If this is not done damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not the hard plastic sealing boot and soft rubber 10. With trim stick inserted between sealing boot and tripod joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint housing. This procedure will equalize the air pressure in the tripod joint, preventing premature sealing boot failure. 11. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recess's of the tripod housing. 12. Clamp tripod joint sealing boot to tripod joint, using required procedure for type of boot clamp application. CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp: Clamp sealing boot onto tripod housing using Crimper, Special Tool C-4975-A. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3849 Fig. 37 - Place crimping tool C-4975-A over bridge of clamp. Fig. 38 - Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp: Clamp sealing boot onto tripod housing using clamp locking tool, Snap-On YA3050 or an equivalent. Fig. 39 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3850 - Place prongs of clamp locking tool in the holes of the clamp. Fig. 40 - Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp. 13. Install the driveshaft back on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3851 Constant Velocity Joint Boot: Service and Repair Outer C/V Joint Sealing Boot REMOVAL To remove outer C/V joint sealing boot from a driveshaft for replacement, the driveshaft assembly must be removed from the vehicle. See Driveshaft Removal and Installation for the required driveshaft removal and replacement procedure. 1. Remove driveshaft assembly requiring boot replacement from vehicle. Fig. 41 2. Remove large boot clamp retaining C/V joint sealing boot to C/V joint housing and discard. Remove small clamp that retains outer C/V joint sealing boot to interconnecting shaft and discard. Remove sealing boot from outer C/V joint housing and slide it down interconnecting shaft. Fig. 42 3. Wipe away grease to expose outer C/V joint to interconnecting shaft retaining ring. Spread ears apart on C/V joint assembly to interconnecting shaft retaining snap ring. Slide outer C/V joint assembly off end of interconnecting shaft. 4. Slide failed sealing boot off interconnecting shaft. 5. Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable. INSTALLATION 1. Slide a new seal boot to interconnecting shaft retaining clamp, onto the interconnecting shaft. Then slide the replacement outer C/V joint assembly sealing boot onto the interconnecting shaft. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3852 Fig. 43 2. Install outer C/V joint assembly onto interconnecting shaft. Joint is installed on interconnecting shaft, by pushing interconnecting shaft into outer C/V joint, until retaining snap ring is seated in groove on interconnecting shaft. Verify the snap ring is fully seated into groove on interconnecting shaft. 3. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer C/V joint assembly housing. Put the remaining amount into the sealing boot. Fig. 44 4. Install outer C/V joint seal boot retaining clamp, onto interconnecting shaft. Install replacement outer C/V joint sealing boot onto interconnecting shaft. Outer C/V joint seal boot MUST be positioned on interconnecting shaft, so only the thinnest (sight) groove on interconnecting shaft is visible. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3853 Fig. 45 Fig. 46 5. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 6. Position outer C/V joint sealing boot into its retaining groove on outer C/V joint housing. Install sealing boot to outer C/V joint retaining clamp evenly on sealing boot. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3854 Fig. 47 Fig. 48 7. Clamp sealing boot onto outer C/V joint housing using Crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. 8. Install the driveshaft requiring boot replacement back on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications TORQUE SPECIFICATIONS Drive Plate-to-Crankshaft Bolts ........................................................................................................... ..................................................... 95 Nm (70 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications Control Module: Specifications Sixty-Way Connector 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications > Page 3870 Transmission Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3892 Control Module: Description and Operation AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT The electronic automatic transaxle control module and the PCM supply information to each other through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the information when adjusting the fuel and ignition strategy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3893 Control Module: Service and Repair OVERVIEW Do not interchange Transmission Control Modules with previous year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. REMOVAL Fig. 27 1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then disconnect the 60 way connector on Transmission Control Module. Fig. 28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3894 Fig. 29 2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28 and 29). INSTALLATION 1. To install, reverse removal procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3898 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3899 Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3900 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY The transmission control relay is located in the Power Distribution Center (PDC) on the left side of the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in mode. After a controller reset (ignition key turned to the run position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Autostick/Overdrive Off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3906 Autostick/Overdrive Switch Connector Pin Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3910 Transmission Mode Switch: Diagrams For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3915 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3916 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3917 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3918 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3919 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3920 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3921 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3930 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3936 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3937 Transmission Speed Sensor: Specifications Speed Sensor Input 20 ft.lb Output 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3938 Input Speed Sensor/Output Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3941 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor Transmission Speed Sensor: Service and Repair Input Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 25 The input speed sensor is located to the left of the manual shift lever (Fig. 25). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 3944 Transmission Speed Sensor: Service and Repair Output Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 26 The output speed sensor is located to the right of the manual shift lever (Fig. 26). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Power Transfer Unit ............................................................................................................................. ........................................................ 1.2L (2.4 Pints) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 3950 Fluid - Transfer Case: Fluid Type Specifications Power Transfer Unit Viscosity .............................................................................................................................................. .............................................................. SAE 85W-90 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 3951 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations A604 (41TE) 4 Speed Transaxle Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications Control Module: Specifications Sixty-Way Connector 35 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications > Page 3963 Transmission Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3985 Control Module: Description and Operation AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT The electronic automatic transaxle control module and the PCM supply information to each other through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the information when adjusting the fuel and ignition strategy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3986 Control Module: Service and Repair OVERVIEW Do not interchange Transmission Control Modules with previous year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. REMOVAL Fig. 27 1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then disconnect the 60 way connector on Transmission Control Module. Fig. 28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 3987 Fig. 29 2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28 and 29). INSTALLATION 1. To install, reverse removal procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3991 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3992 Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3993 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY The transmission control relay is located in the Power Distribution Center (PDC) on the left side of the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in mode. After a controller reset (ignition key turned to the run position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Autostick/Overdrive Off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3999 Autostick/Overdrive Switch Connector Pin Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4003 Transmission Mode Switch: Diagrams For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 4008 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 4009 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4010 Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4011 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4012 Transmission Position Switch/Sensor: Description and Operation Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transaxle housing. If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park neutral switch is sometimes referred to as the neutral safety switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4013 Transmission Position Switch/Sensor: Service and Repair The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. Fig. 20 3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. Fig. 21 11. Place valve body on workbench (Fig. 21). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4014 Fig. 22 12. Remove TRS retaining screw (Fig. 22). Fig. 23 13. Remove manual shaft seal (Fig. 23). Fig. 24 14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24). INSTALLATION 1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.) Reseal transaxle oil pan using RTV. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4023 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4029 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4030 Transmission Speed Sensor: Specifications Speed Sensor Input 20 ft.lb Output 20 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4031 Input Speed Sensor/Output Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 4034 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor Transmission Speed Sensor: Service and Repair Input Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 25 The input speed sensor is located to the left of the manual shift lever (Fig. 25). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 4037 Transmission Speed Sensor: Service and Repair Output Sensor CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Fig. 26 The output speed sensor is located to the right of the manual shift lever (Fig. 26). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The amber ABS warning lamp is located on the right side of the message center located at the top of the instrument panel. When the ignition key is turned to the ON position, the amber ABS warning lamp is lit until the CAB completes its self-tests and turns off the lamp (approximately 4 seconds). The amber ABS warning lamp will illuminate when the CAB detects a condition that results in the shutdown of ABS function, or when the body controller does not receive a CCD message from the CAB. The CAB turns on the amber ABS warning lamp by grounding the circuit. Under most conditions, when the amber ABS warning lamp is on, only the ABS function of the brake system is affected; the base brake system and the ability to stop the vehicle are not affected. The amber ABS warning lamp is controlled by the CAB and the body controller through a diode located in the junction block. The CAB and body controller control the amber ABS warning lamp by directly grounding the circuit. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Page 4043 ABS Light: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES The ABS system fuse and the ABS pump/motor fuse are located in the Power Distribution Center (PDC). Refer to the sticker on the inside of the PDC cover for the location of these fuses. The PDC is located on the driver's side of the engine compartment. The fuse for the amber ABS warning lamp is located in the fuse junction block under the instrument panel. If the vehicle is equipped with traction control, the fuse for the traction control switch is located in the fuse junction block under the instrument panel. ABS RELAYS Two relays are used to control the antilock brake system. The two relays are the pump/motor relay and the system relay. The pump/motor relay and the system relay are located in the CAB. If either the pump/motor relay or the system relay is diagnosed as not functioning properly, the CAB must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations Hydraulic Control Unit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations > Page 4050 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications To HCU Mounting Bolts ....................................................................................................................... .................................................. 2 Nm (17 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4054 Controller Antilock Brake (CAB) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4055 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4056 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the ABS system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the CCD bus. The primary functions of the (CAB) are to: 1. monitor the antilock brake system for proper operation. 2. detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. 3. control fluid modulation to the wheel brakes while the system is in an ABS mode or the traction control system is activated. 4. store diagnostic information. 5. provide communication to the DRB scan tool while in diagnostic mode. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn on the amber ABS warning lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning lamp is turned on and the fault Diagnostic Trouble Code (DTC) is then stored in a diagnostic program memory. These DTCs will remain in the CAB memory even after the ignition has been turned off. The DTCs can be read and cleared from the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 255 key cycles of vehicle operation or 3,600 miles, whichever comes first. CONTROLLER ANTILOCK BRAKE INPUTS - wheel speed sensors (four) - stop lamp switch - ignition switch - system relay voltage - ground. - traction control lamp (if equipped) - diagnostic communication (CCD) CONTROLLER ANTILOCK BRAKE OUTPUTS - body controller communication - amber ABS warning lamp actuation - traction control lamp (if equipped) - diagnostic communication (CCD) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Mounting Bracket To Suspension Cradle Bolts .................................................................................................................................. 28 Nm (250 inch lbs.) To Mounting Bracket Isolator Attaching Bolts ..................................................................................................................................... 11 Nm (97 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4060 Hydraulic Control Unit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4061 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Teves Mark 20 ICU The Hydraulic Control Unit (HCU) is mounted to the CAB as part of the ICU. The ICU is located on the driver's side of the front suspension cradle under the vehicle. The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is approximately 1 inch longer on the low pressure fluid accumulators side than a HCU on a vehicle that is equipped with only ABS. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. On vehicles with traction control, there is an extra set of valves and solenoids. The ASR valves, mounted in the HCU valve block, are normally in the open position and close only when the traction control is applied. These isolator valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is being applied. The rear brakes need to be isolated from the master cylinder when traction control is being applied so the rear wheels do not drag. For more information, see Traction Control System. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU-one for the primary hydraulic circuit and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 5 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. On ABS-only vehicles, there is a mini-accumulator on the secondary hydraulic circuit that protects the master cylinder seals during an ABS stop, and there is a noise dampening chamber on the primary circuit. On ABS with traction control vehicles, there are two noise dampening chambers in the HCU. PUMP/MOTOR There are two pump assemblies in the HCU-one for the primary hydraulic circuit and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the CAB. The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, one piston draws fluid from the accumulators, and the opposing piston pumps fluid to the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The CAB may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4062 after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Replacement Removal NOTE: Before proceeding, review all SERVICE WARNINGS AND CAUTIONS in Service Precautions. 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the HCU. 3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. CAB 25 Way Connector 4. Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. Unlocked 25 Way CAB Connector 5. Remove the 25 way connector from the CAB. The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will raise and unlock the 25 way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. 6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4065 Brake Tube Connections To HCU 7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. ICU To Suspension Cradle Mounting Bolts 8. Remove the 3 bolts attaching the ICU mounting bracket to the front suspension crossmember. 9. Remove ICU and the mounting bracket as a unit from the vehicle. ICU Mounting Bolts 10. Remove the 3 bolts mounting the ICU to the mounting bracket. Separate the ICU from the mounting bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4066 11. Refer to Overhaul for the procedure on separating and attaching the CAB to the HCU. Installation 1. Install the ICU on the mounting bracket. Install the 3 bolts attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front suspension crossmember. 2. Install the ICU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the ICU bracket to the crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). Brake Tube Connections To HCU CAUTION: ^ Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. ^ When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to the image for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the ICU mounting bracket. 3. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. 4. Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle. 5. Clip the cab wiring harness to the ICU mounting bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4067 Brake Tube Routing Clips 6. Install the routing clips on the brake tubes. 7. Lower the vehicle. 8. Connect negative cable back on negative post of the battery. 9. Bleed the base and ABS hydraulic systems. 10. Road test vehicle to ensure proper operation of the base and antilock brake systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4068 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Overhaul REMOVAL NOTE: To replace the Hydraulic Control Unit (HCU) or the Controller Antilock Brake (CAB) on this vehicle, the entire Integrated Control Unit (ICU) needs to be removed from the vehicle. The CAB can then be separated from the HCU. Do not attempt to replace the CAB with the ICU mounted in the vehicle. 1. Remove the ICU from the vehicle. Pump/Motor To CAB Wiring Harness 2. Disconnect the pump/motor wiring harness from the CAB. CAB Attaching Bolts 3. Remove the 4 bolts attaching the CAB to the HCU. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4069 Remove/Install CAB 4. Remove the CAB from the HCU. INSTALLATION 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle. 5. Bleed the base and ABS hydraulic systems. 6. Road test the vehicle to ensure proper operation of the base brakes and ABS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection Traction Control Indicator Lamp: Testing and Inspection The traction control light is tested by cycling the traction control switch on and off. The traction control switch used on this vehicle is a momentary contact type switch. The test procedure for the traction control light is performed as follows: Press the traction control switch once and the TRAC OFF lamp will illuminate. With the TRAC OFF lamp illuminated, press the traction control switch again and the TRAC OFF lamp will turn off. If the traction control lamp does not function as described in the test above, diagnosis of the traction control switch, lamp, wiring and other related components of the traction control system is required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Traction Control Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Harness Side Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Harness Side > Page 4078 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Page 4079 Traction Control Switch: Testing and Inspection Traction Control Switch Connector 1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading between pins. Traction Control Switch Continuity Switch Position = Continuity between Actuated = Pins 1 and 2 Illumination = Pins 1 and 3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Page 4080 Traction Control Switch: Service and Repair Battery Negative Cable REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the over steering column bezel. 3. Remove the two screws attaching traction control switch to the bezel. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Allowable Resistance 900 - 1300 ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 4085 Wheel Speed Sensor: Mechanical Specifications Front Rear Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in To Axle Or Steering Knuckle Mounting Bolt 105 in.lb 105 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Front Wheel Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 4088 Rear Wheel Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4091 Wheel Speed Sensor: Diagrams Rear Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 4092 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor (FWD) One Wheel Speed Sensor (WSS) and one tone wheel are located at each front and rear wheel. Each front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is part of the outboard constant velocity joint. The rear wheel speed sensor on rear disc brake applications is mounted to the rear disc brake adapter. The rear tone wheel is an integral part of the rear wheel hub and bearing. The wheel speed sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel speed sensor. The CAB converts the AC signal into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. Correct ABS operation is dependent on accurate wheel speed signals. The vehicle's tires and wheels all must be the same size and type to generate accurate signals. Variations in tire and wheel size can produce inaccurate wheel speed signals. Improper speed sensor-to-tone wheel clearance can cause erratic speed sensor signals. The speed sensor air gap is not adjustable, but should be checked when applicable. Wheel speed sensor-to-tone wheel clearance specifications can be found in Specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 4093 Wheel Speed Sensor: Testing and Inspection Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. missing, chipped, or broken teeth - contact with the wheel speed sensor - wheel speed sensor to tone wheel alignment - wheel speed sensor to tone wheel clearance - excessive tone wheel runout - tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement on front-wheel-drive models, the tone wheel is serviceable separately. If a rear tone wheel is found to need replacement on all-wheel-drive models, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Front Speed Sensor Cable Channel Bracket 3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame rail. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector. Speed Sensor Cable To Vehicle Wiring Harness 4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect speed sensor cable from vehicle wiring harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4096 Front Wheel Speed Sensor Attaching Bolt 5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. Front Wheel Speed Sensor Cable Routing 7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front wheel speed sensor assembly from the vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut tower. CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the channel bracket. 2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4. Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link. 5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor attaching bolt to a torque of 12 Nm (105 inch lbs.) 6. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (.047 inches). 7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4097 Rear REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. CAUTION: When unplugging speed sensor cable from vehicle wiring harness, be careful not to damage pins on the electrical connectors. Also inspect connectors for any signs of previous damage. Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during removal of the speed sensor cable. Speed Sensor Cable Attachment To Brake Flex Hose 4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4098 Right Rear Speed Sensor Cable Routing 5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the axle flange, the brake tube clip and the routing clip from the track bar bracket on the axle. Rear Speed Sensor Routing Brackets And Clips 6. Remove the 2 rear wheel speed sensor cable/brake tube routing clips. Then unclip the speed sensor cable from the routing clips on rear brake tube. CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor head in an attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the sensor from side to side until free. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4099 Rear Wheel Speed Sensor Attaching Bolts 7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not come loose, do not use pliers. Tap with screw driver and hammer. 8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed sensor assembly from vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head. Note the plastic anti rotation pin must be fully seated prior to installing the attaching bolt. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. Rear Wheel Speed Sensor Attaching Bolts 2. Install the wheel speed sensor head to bearing flange attaching bolt. Tighten the attaching bolt to a torque 12 Nm (105 inch lbs.) 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inches). 4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle. The rear wheel speed sensor cable should be routed under the rear brake tube. CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during installation of the wheel speed sensor cable. 5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4100 CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the vehicle wiring harness, do not force the connectors together. If the connectors are forced together, damage to the connectors will occur. 7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into the body hole. 9. Install the tire and wheel assembly on vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4101 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement This procedure is for the removal of the ABS rear tone wheel from the rear hub and bearing on front wheel drive vehicles. Vehicles equipped with AWD have a tone wheel mounted on the driveshaft outer constant velocity joint and it is serviced with the driveshaft. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly. 3. Remove rear brake drum from the hub/bearing assembly. Rear Wheel Speed Sensor 4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing assembly. Rear Hub/Bearing Mounting Bolts 5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4102 Removing Rear Hub/Bearing From Axle 6. Remove the hub/bearing assembly from the rear axle and brake support plate. Tone Wheel Removal From Hub/Bearing Assembly 7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage by the vise jaws. Mount the hub/bearing assembly in a vise. Using Puller, Special Tool C-4693 installed as shown remove the tone wheel from the hub/bearing assembly. INSTALL Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4103 Installing Tone Wheel On Hub/Bearing Assembly 1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3. Position Driver, Special Tool 6908-1 with undercut side facing up on top of the tone wheel. Correctly Installed Tone Wheel 2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3. Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts into hub/ bearing assembly. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 7. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 8. Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inches). 9. Install the brake drum onto the rear hub/bearing assembly. 10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust the rear brakes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures Bleeding Base Brake Hydraulic System NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake System bleeding procedure in antilock brakes. Pressure Bleeding Procedure CAUTION: - Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. - Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the hydraulic system for bleeding. - When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system is pressurized. Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment. Air Trapped In Brake System When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. 1. Remove the filler neck from the master cylinder fluid reservoir. Pressure Bleeding Cap Installed On Master Cylinder 2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the fluid reservoir of the master cylinder. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent. 3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 4108 adequate removal of all trapped air from the brake hydraulic system. (1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel Rear Wheel Cylinder Bleeder Screw 4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid discharge will NOT get all the air out. 5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Bleeding Without A Pressure Bleeder NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are correctly adjusted. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 4109 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brake hydraulic system, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure or standard pressure bleeding equipment. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRB. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Base Brake Bleeding. 5. Using the DRB, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Pedal Ratio .......................................................................................................................................... ............................................................................ 3.36 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The red BRAKE warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank position. The warning lamp bulb is supplied a 12-volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the parking brake switch, the fluid level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the crank position. The Brake Fluid Level switch is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the switch is to provide the driver with an early warning that brake fluid level in the master cylinder fluid reservoir has dropped to below normal. This may indicate: Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. - Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level switch closes to ground the brake warning light circuit. This will turn on the red BRAKE warning Light. At this time, the master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 4116 Brake Warning Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4126 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4127 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4128 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4129 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4130 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4136 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4137 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4138 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4139 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4140 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 4141 Brake Caliper: Specifications Caliper Mounting Bolts 30 ft.lb Guide Pin Bolts 195 in.lb Bleeder Screw 125 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front NOTE: Before proceeding with this procedure, review Service Precautions. REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Remove the two caliper to steering knuckle guide pin bolts. Caliper Assembly Mounting On Steering Knuckle (Typical) 4. Remove caliper from steering knuckle by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4144 Storing Front Disc Brake Caliper 5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex hose. Supporting weight of caliper by the brake fluid flex hose, can damage the flexible brake hose. INSTALLATION 1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper end of caliper over the machined abutment on steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 3. Install the caliper guide pin bolts and tighten to a torque of 22 Nm (195 inch lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 4. Install the wheel and tire assembly. 5. Using a torque wrench, tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. Rear NOTE: Before proceeding with this procedure, review Service Precautions. - Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4145 Removing Caliper Guide Pin Bolts 3. Remove the disc brake caliper to adapter guide pin bolts. Removing/Installing Caliper 4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. Correctly Supported Caliper 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4146 INSTALLATION NOTE: Step 1 below is only required when installing the disc brake caliper after new brake pads have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal. CAUTION: When installing guide pin bolts, extreme caution should be taken not to crossthread them. 5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 8. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4147 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly and Assembly DISASSEMBLY WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the first inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston from opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4148 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). 11. If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. NOTE: ^ When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. ^ Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4149 ASSEMBLY CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise (with protective caps installed on jaws of vise). Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled. 3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4150 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. 9. Install brake pads. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs.). New seal washers must always be used when installing brake hose to caliper. 12. Bleed the brake system. Guide Pin Bushing Service The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure. REMOVING CALIPER GUIDE PIN BUSHINGS 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Removing Inner Sleeve From Bushing Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4151 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. INSTALLING CALIPER GUIDE PIN BUSHINGS Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4152 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4153 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4154 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4155 Brake Caliper: Service and Repair Cleaning and Inspection Front If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the shoe and lining assemblies. Combined shoe and lining thickness should be measured at the thinnest part of the assembly. When a shoe and lining assembly is worn to a thickness of approximately 7.95 mm (0.313 inch) it should be replaced. Replace both shoe assemblies (inboard and outboard) on the front wheels. It is also necessary that both front wheel shoe assembly sets be replaced, whenever shoe assemblies on either side of the vehicle require replacement. If a shoe assembly does not require replacement, reinstall it, making sure each shoe assembly is returned to its original position. Rear Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front Brake Pad: Specifications Front Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) or less, they should be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 4160 Brake Pad: Specifications Rear Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch), they should be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front NOTE: Before proceeding with this procedure, review Service Precautions. REMOVAL 1. Remove the caliper from the disc brake rotor. Removing Outboard Brake Pad From Caliper 2. Remove outboard brake pad by prying the pad retaining clip over raised area on caliper. Then slide the pad down and off the caliper. Removing Inboard Brake Pad From Piston 3. Pull inboard brake pad away from piston until retaining clip on brake pad is free from cavity in caliper piston. INSTALLATION 1. Completely retract caliper piston back into piston bore of caliper assembly. This is required for caliper installation with new brake pad assemblies. 2. Remove the protective paper from the noise suppression gasket on both the inner and outer brake pad assemblies (if equipped). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4163 Front Brake Shoe Assembly Identification NOTE: The inboard and outboard brake pads are not common, refer to the image for inboard and outboard brake pad assembly identification. Inboard Brake Shoe 3. Install the new inboard brake pad assembly into the caliper piston by firmly pressing into piston bore. Be sure inboard brake pad assembly is positioned squarely against face of caliper piston. Installing Outboard Brake Shoe 4. Slide the new outboard brake pad assembly onto the caliper assembly. 5. Reinstall the caliper on the brake rotor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4164 Brake Pad: Service and Repair Rear Removal and Installation NOTE: Before proceeding with this procedure, review Service Precautions. REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. Caliper Guide Pin Bolts 3. Remove the caliper to adapter guide pin bolts. Removing/Installing Caliper 4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard anti-rattle clip out from under the front abutment on the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4165 Correctly Supported Caliper 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 6. If the brake rotor needs to be removed it can be removed by removing the retainer clips and then pulling the rotor straight off the wheel mounting studs. 7. Remove the outboard brake pad from the caliper. Brake pad is removed by prying brake shoe retaining clip over raised area on caliper and sliding the brake pad off the caliper. Removing Inboard Brake Pad From Piston 8. Remove inboard brake pad from caliper. Inboard pad is removed by pulling it out of the caliper piston, until the retaining clip is free of the piston. CALIPER INSPECTION Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if scored). Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. INSTALLATION NOTE: Step 1 below is only required when installing a caliper after new brake pads have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4166 Inboard Brake Shoe 4. Install the inboard brake pad into the caliper piston by firmly pressing it into the piston bore using your thumbs. Be sure inboard pad is positioned squarely against the face of the caliper piston. 5. Install the outboard brake pad on the disc brake caliper. Be sure the outboard pad is positioned squarely against the outboard fingers of the caliper. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 6. Carefully lower caliper and brake pads over rotor and onto adapter, reversing the removal procedure. CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to crossthread them. 7. Install the caliper guide pin bolts. Tighten to a torque of 22 Nm (192 inch lbs.). 8. Install the wheel and tire assembly. 9. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 10. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop the vehicle. 11. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. Cleaning and Inspection LINING WEAR If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the rear disc brake pads. The combined shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake pads are worn to a total thickness of approximately 7.0 mm (9/32 inch) they should be replaced. Replace both brake pad assemblies (inboard and outboard). It is necessary that both rear wheel sets be replaced whenever brake shoe assemblies on either side are replaced. If the brake shoe assemblies do not require replacement, reinstall, the assemblies making sure each brake shoe is returned to the original position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Brake Rotor Specifications Brake Rotor Specifications BRAKE ROTOR Front Rear BRAKE ROTOR TYPE Ventilated Solid BRAKE ROTOR DIAMETER (14"/15" Standard) 260 mm (10.24 in.) 381 mm (15.0 in.) BRAKE ROTOR DIAMETER (15" Heavy Duty) 283 mm (117.92 in.) ----ROTOR THICKNESS 23.87 - 24.13 mm (0.939 - 0.949 in.) 12.25 - 12.75 mm (0.482 - 0.502 in.) MINIMUM ROTOR THICKNESS 22.4 mm (0.881 in.) 11.25 mm (0.443 in.) Minimum allowable thickness markings are cast/stamped on an un-machined outer surface of the rotor. These thickness markings include 0.76 mm (0.030 in.) allowable rotor wear beyond the recommended 0.76 mm (0.030 in.) of rotor refacing. ROTOR THICKNESS VARIATION 0.013 mm (0.0005 in.) 0.013 mm (0.0005 in.) ROTOR RUNOUT * 0.08 mm (0.003 in.) 0.08 mm (0.003 in.) * TIR - Total Indicator Reading (measured on vehicle) ROTOR MICRO-FINISH 15 - 80 RMS 15 - 80 RMS Front Rotor Thickness Markings Rear Rotor Thickness Markings Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4170 Brake Rotor/Disc: Testing and Inspection Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be checked and inspected. BRAKING SURFACE INSPECTION Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake pads are installed, improper wear of the pads will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake pads at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake pad contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Minimum Brake Rotor Thickness Markings (Typical) Minimum thickness specifications are cast on the rotor's unmachined surface. Limits can also be found in SPECIFICATIONS. ROTOR THICKNESS VARIATION Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4171 Checking Rotor For Thickness Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor at 12 equal points around the rotor braking surface with a micrometer at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary by more than 0.013 mm (0.0005 inch), the rotor should be refaced or replaced. ROTOR RUNOUT Checking Rotor Runout On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first remove the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the rotor to the hub. Mount the Dial Indicator, Special Tool C-3339, with Mounting Adaptor, Special Tool SP1910 on steering arm. The dial indicator plunger should contact braking surface of rotor approximately ten millimeters from edge of rotor. Check lateral runout on both sides of the rotor, marking the low and high spots on both. Runout limits can be found in SPECIFICATIONS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4172 Marking Rotor And Wheel Stud If runout is in excess of the specification, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed. Remove the rotor from the hub. NOTE: Clean the hub face surface before checking runout. This provides a clean surface to get an accurate indicator reading. Checking Hub Runout Mount Dial Indicator, Special Tool C-3339, and Mounting Adaptor, Special Tool SP-1910, to the steering knuckle. Position the indicator stem so it contacts the hub face near the outer diameter. Care must be taken to position stem outside of the stud circle, but inside of the chamfer on the hub rim. Hub runout should not exceed 0.03 mm (0.0012 inch). If runout exceeds this specification, the hub must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4173 Index Rotor And Wheel Stud Brake Rotor Limits If the hub runout does not exceed this specification, install the rotor back on the hub, aligning the chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud. Tighten nuts in the proper sequence and torque to specifications. Recheck brake rotor runout to see if the runout now within specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4174 Brake Rotor/Disc: Service and Repair MACHINING Brake Rotor Limits NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. On-Car Brake Lathe If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe, or replaced. The use of a hub-mounted on-car brake lathe is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing. Minimum Brake Rotor Thickness Markings (Typical) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4175 Rear Rotor Thickness Markings NOTE: All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor. Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Before installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4181 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4182 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4183 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4184 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4185 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4186 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4187 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 4188 Backing Plate: Specifications To Rear Axle Mounting Bolts ............................................................................................................... ................................................. 130 Nm (95 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal Backing Plate: Service and Repair Removal 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and tire. 3. Remove brake drum from hub/bearing. 4. Remove brake shoes from brake support plate. 5. Disconnect the park brake cable from the park brake actuation lever. 6. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first. CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on the tone wheel will result in false ABS cycling and corrosion of the tone wheel. 7. Remove the 4 bolts attaching the hub/bearing to the flange of the rear axle. CAUTION: Corrosion may occur between the hub/bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/ bearing will not come out of the axle by pulling on it by hand, do not pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/bearing. This damage will result in noise or failure of the bearing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 4191 8. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 and following procedure to press the hub/bearing out of the axle. a. Place Special Tool 8214-1 over tone wheel and against cast flange of hub/bearing. Put a dab of grease in the bolt pilot hole on the back of Special Tool 8214-1. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. Special Tool 8214-2 should be against and supported by the axle plate when pressing the wheel bearing out of the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until tool fits properly. c. Align bolt in Special Tool 8214-2 with pilot hole in Special Tool 8214-1. Tighten bolt against Special Tool 8214-1. d. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special Tool 8214-1. 9. Remove the hub/bearing from the rear axle and brake support plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 4192 10. Using a suitable tool such as a 14 mm box wrench or an aircraft type hose clamp, compress the flared legs on park brake cable retainer, then pull the park brake cable out of brake support plate. 11. Lower vehicle enough to access the brake pedal. 12. Using a brake pedal depressor, move brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of master cylinder when brake tube is removed from wheel cylinder. 13. Raise vehicle. 14. Disconnect brake tube from wheel cylinder. 15. Remove the 2 bolts attaching the wheel cylinder to the brake support plate. 16. Remove the wheel cylinder from the brake support plate. 17. Remove the rear brake support plate from the rear axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 4193 Backing Plate: Service and Repair Installation 1. Install the 4 hub/bearing to axle mounting bolts into the mounting holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. NOTE: When installing the hub/bearing on the rear axle, the bearing is to be installed with the thick bearing mounting flange pointing down. 3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 5. Apply sealant such as Mopar Gasket-In-A-Tube or an equivalent around the wheel cylinder opening in the brake support plate. 6. Install wheel cylinder onto brake support and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.). 7. Install brake tube on rear wheel cylinder. Tighten tube nut to a torque of 16 Nm (142 inch lbs.). 8. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 9. Install the rear park brake cable into its mounting hole in the rear brake support plate. 10. Install the park brake cable on the park brake actuation lever. 11. Install the rear brake shoes on the brake support plate. 12. Install brake drum onto hub/bearing. 13. Install wheel and tire. 14. Tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 15. Adjust the rear brakes. 16. Bleed the entire brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4198 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4199 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4200 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4201 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4202 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4203 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4204 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 4205 Brake Drum: Specifications Brake Drum Specifications Brake Drum Specifications DRUM DIAMETER 250 mm (9.84 in.) DRUM DIAMETER (Maximum) Cast/stamped into outside surface of drum This marking includes 0.76 mm (0.030 inch) for allowable drum wear beyond the recommended 1.52 mm (0.060 inch) of drum refacing. DIAMETER VARIATION (Maximum) 0.090 mm (0.004 in.) DRUM RUNOUT (on lathe) 0.15 mm (0.006 in.) INITIAL DRUM MACHINING CUTS 0.13 mm (0.005 in.) Initial machining cuts should be limited to 0.13 mm (0.005 in.) at a time as heavier feed rates can produce taper and surface variation. FINISH DRUM MACHINING CUTS 0.0254 mm (0.001 in.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation Brake Drum: Service and Repair Brake Drum Removal and Installation REMOVAL 1. Remove the tire and wheel assembly from the vehicle. Remove the park brake cable for the wheel of the vehicle that is being worked on, from the parking brake cable equalizer). This is required to gain access to the star wheel. If the cable is not removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel. 2. Remove the rear brake shoe adjusting hole cover plug. 3. Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw star wheel. 4. Insert Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake adjustment by prying down with adjusting tool. 5. Remove rear brake drum from rear hub/bearing assembly. INSTALLATION 1. Adjust brake shoe assemblies so as not to interfere with brake drum installation. 2. Install the rear brake drums on the hubs. 3. Adjust rear brake shoes. Parking Brake Cable Equalizer 4. Install the removed park brake cable back on the park brake cable equalizer. 5. Install wheel and tire. 6. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation > Page 4208 Brake Drum: Service and Repair Brake Drum Refinishing Measure the runout and diameter of the rear brake using only accurate measuring equipment. There should be no variation in the drum diameter greater than 0.090 mm (0.004 inch). Drum runout should not exceed 0.15 mm (0.006 inch) out of round. If the drum runout or diameter variation exceed these values the drum should be refaced. For best results in eliminating the irregularities that cause brake roughness and surge, the amount of material removed during a single cut should be limited to 0.13 mm (0.005 inch). When the entire braking surface has been cleaned. A final cut of 0.0254 mm (0.001 inch) will assure a good drum surface providing the equipment used is capable of the precision required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks. Do not reface more than 1.52 mm (0.060 inch) over the standard drum diameter. All drums will show markings of maximum allowable diameter. For example, a drum will have a marking of MAXIMUM DIAMETER 251.55 mm (9.90 inch). This marking includes 0.76 mm (0.030 inch) for allowable drum wear beyond the recommended 1.52 mm (0.060 inch) of drum refacing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4213 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4214 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4215 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4216 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4217 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4218 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4219 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4220 Brake Shoe: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4221 Brake Shoe: Adjustments NOTE: Normally, self adjusting drum brakes will not require manual brake shoe adjustment. Although in the event of a brake reline it is advisable to make the initial adjustment manually to speed up the adjusting time. 1. Raise the vehicle so that the rear wheels are free to turn. Park Brake Cable Equalizer Remove the park brake cable for the wheel of the vehicle that is being worked on from the park brake cable equalizer. This is required to gain access to the star wheel. If the cable is not removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel. 2. Remove rubber plug, from rear brake adjusting hole, in the rear brake support plate. 3. Be sure parking brake lever is fully released. 4. Insert Brake Adjusting Special Tool C-3784 or equivalent through the adjusting hole in support plate and against star wheel of adjusting screw. Move handle of tool upward until a slight drag is felt when road wheel is rotated. 5. Insert a thin screwdriver or piece of welding rod into brake adjusting hole. Push adjusting lever out of engagement with star wheel. Care should be taken so as not to bend adjusting lever or distort lever spring. While holding adjusting lever out of engagement, back off star wheel to ensure a free wheel with no brake shoe drag. 6. Repeat above adjustment at the other rear wheel. 7. Install adjusting hole rubber plug in rear brake support plates. 8. Install park brake cables on park brake cable equalizer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation Removal NOTE: Before proceeding with this procedure, review Service Precautions. 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove the rear wheel and tire assemblies from the vehicle. 3. Remove rear brake drum to hub retaining nuts (if equipped). Then remove rear brake drums from hub and bearing assemblies. NOTE: When creating slack in the park brake cables by locking out the automatic adjuster, be sure that the park brake pedal is in the released (most upward) position. 4. Create slack in the rear park brake cables. Slack is created by grabbing exposed section of front park brake cable and pulling it down and rearward. Slack is maintained in the park brake cable by installing a pair of locking pliers on the park brake cable just rearward of only the rear body outrigger bracket. 5. Remove adjustment lever spring from adjustment lever and front brake shoe. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4224 6. Remove adjustment lever from leading brake shoe. 7. Remove the brake shoe to brake shoe lower return springs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4225 8. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly. 9. Remove the brake shoe to brake shoe upper return spring. 10. Remove the trailing brake shoe assembly to brake support plate hold down spring and pin from the brake shoe assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4226 11. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and park brake actuating strut. Remove the automatic adjuster assembly from the leading brake shoe. 12. Remove the leading brake shoe assembly to brake support plate hold down spring and pin from the brake shoe. Remove the leading brake shoe from the brake support plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4227 13. Remove the park brake actuator from the leading brake shoe and transfer to the replacement brake shoe. Installation 1. Lubricate the eight shoe contact areas on the support plate and anchor, using the required special Mopar Brake Lubricant. 2. Install leading brake shoe on brake support plate. Install the leading brake shoe hold down spring and pin on the brake shoe. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4228 3. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 4. Install the automatic adjuster screw on the leading brake shoe. Then install the trailing brake shoe on the park brake actuating lever and park brake actuating strut. Position trailing brake shoe on brake support plate. 5. Install the brake shoe hold down pin and spring on the trailing brake shoe. 6. Install the brake shoe to brake shoe upper return spring. CAUTION: When installing the tension clip on the automatic adjuster, it must be located on only the threaded area of the adjuster assembly. If it is located on a non-threaded area of the adjuster, the function of the automatic adjuster will be affected. 7. Install the tension clip attaching the upper return spring to the automatic adjuster assembly. 8. Install the brake shoe to brake shoe lower return springs on the brake shoes. 9. Install automatic adjustment lever on the leading brake shoe of the rear brake assembly. 10. Install the actuating spring on the automatic adjustment lever and leading brake shoe assembly. 11. Verify that the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 12. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 13. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 14. Install the rear brake drums on the hubs. 15. Adjust rear brake shoes. 16. Install the wheel and tire assembly. 17. Push the park brake pedal to the floor once and release pedal. This will automatically remove the slack from and correctly adjust the park brake cables. 18. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 130 Nm (95 ft. lbs.). 19. Road test vehicle. The automatic adjuster will continue the brake adjustment during the road test of the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4229 Brake Shoe: Service and Repair Cleaning and Inspection LINING 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the rear brake adjusting hole cover plug. 3. Insert a thin screwdriver into brake adjusting hole to hold the adjusting lever away from the notches on the adjusting screw star wheel. 4. Insert Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake by prying down with adjusting tool. 5. Remove the rear brake drum from the rear hub/bearing assembly. 6. Inspect brake lining for wear, shoe alignment, and or contamination from grease or brake fluid. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Diameter 3/4 in To Support Plate Mounting Bolts 75 in.lb Bleeder Screw 80 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE 1. In case of a leak, remove brake shoes. Replace if soaked with grease or brake fluid. 2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel cylinder attaching bolts. Pull wheel cylinder assembly off the brake support plate. INSTALL 1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4235 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected, and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4236 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: Fig 3 Wheel Cylinder 1. Pry boots away from cylinders and remove. 2. Press in on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol, (DO NOT USE ANY PETROLEUM BASE SOLVENTS) clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.) 4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLE Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with only Mopar Protect A-Cup Lubricant. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures Bleeding Base Brake Hydraulic System NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake System bleeding procedure in antilock brakes. Pressure Bleeding Procedure CAUTION: - Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. - Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the hydraulic system for bleeding. - When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system is pressurized. Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment. Air Trapped In Brake System When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. 1. Remove the filler neck from the master cylinder fluid reservoir. Pressure Bleeding Cap Installed On Master Cylinder 2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the fluid reservoir of the master cylinder. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent. 3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 4242 adequate removal of all trapped air from the brake hydraulic system. (1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel Rear Wheel Cylinder Bleeder Screw 4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid discharge will NOT get all the air out. 5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Bleeding Without A Pressure Bleeder NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are correctly adjusted. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 4243 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brake hydraulic system, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure or standard pressure bleeding equipment. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRB. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Base Brake Bleeding. 5. Using the DRB, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4252 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4253 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4254 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4255 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 4256 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4262 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4263 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4264 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4265 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4266 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 4267 Brake Caliper: Specifications Caliper Mounting Bolts 30 ft.lb Guide Pin Bolts 195 in.lb Bleeder Screw 125 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front NOTE: Before proceeding with this procedure, review Service Precautions. REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Remove the two caliper to steering knuckle guide pin bolts. Caliper Assembly Mounting On Steering Knuckle (Typical) 4. Remove caliper from steering knuckle by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4270 Storing Front Disc Brake Caliper 5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex hose. Supporting weight of caliper by the brake fluid flex hose, can damage the flexible brake hose. INSTALLATION 1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper end of caliper over the machined abutment on steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 3. Install the caliper guide pin bolts and tighten to a torque of 22 Nm (195 inch lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 4. Install the wheel and tire assembly. 5. Using a torque wrench, tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. Rear NOTE: Before proceeding with this procedure, review Service Precautions. - Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4271 Removing Caliper Guide Pin Bolts 3. Remove the disc brake caliper to adapter guide pin bolts. Removing/Installing Caliper 4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. Correctly Supported Caliper 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4272 INSTALLATION NOTE: Step 1 below is only required when installing the disc brake caliper after new brake pads have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal. CAUTION: When installing guide pin bolts, extreme caution should be taken not to crossthread them. 5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 8. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4273 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly and Assembly DISASSEMBLY WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the first inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston from opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4274 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). 11. If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. NOTE: ^ When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. ^ Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4275 ASSEMBLY CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise (with protective caps installed on jaws of vise). Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled. 3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4276 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. 9. Install brake pads. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs.). New seal washers must always be used when installing brake hose to caliper. 12. Bleed the brake system. Guide Pin Bushing Service The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure. REMOVING CALIPER GUIDE PIN BUSHINGS 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Removing Inner Sleeve From Bushing Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4277 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. INSTALLING CALIPER GUIDE PIN BUSHINGS Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4278 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4279 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4280 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4281 Brake Caliper: Service and Repair Cleaning and Inspection Front If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the shoe and lining assemblies. Combined shoe and lining thickness should be measured at the thinnest part of the assembly. When a shoe and lining assembly is worn to a thickness of approximately 7.95 mm (0.313 inch) it should be replaced. Replace both shoe assemblies (inboard and outboard) on the front wheels. It is also necessary that both front wheel shoe assembly sets be replaced, whenever shoe assemblies on either side of the vehicle require replacement. If a shoe assembly does not require replacement, reinstall it, making sure each shoe assembly is returned to its original position. Rear Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4285 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact-rinse eyes thoroughly with water. * Skin Contact-wash skin with soap and water. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4286 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4287 Brake Fluid: Service and Repair MASTER CYLINDER FLUID LEVEL CHECK Check master cylinder reservoir fluid level a minimum of twice annually. Master Cylinder Fluid Level Marks Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid fill level of the master cylinder. If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of the fluid reservoir with brake fluid. Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. Do not use brake fluid with a lower boiling point, as brake failure could result during prolonged hard braking. Use only brake fluid that was stored in a tightly sealed container. Do not use petroleum-based fluid because seal damage will result. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid etc. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for replacement of the brake fluid level switch. REMOVAL Fluid Level Sensor Electrical Connection 1. Remove wiring harness connector from brake fluid reservoir level switch. Master Cylinder Brake Fluid Level Switch 2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert the brake fluid level switch into brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to the brake fluid reservoir. 2. Connect the vehicle wiring harness connector to the brake fluid level switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications To Caliper Banjo Bolt ........................................................................................................................... ................................................... 48 Nm (35 ft. lbs.) Intermediate Bracket .......................................... ................................................................................................................................. 12 Nm (105 inch lbs.) Tube Nuts To Fittings And Components ............................................................................................................................................. 17 Nm (145 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4294 Brake Hose/Line: Description and Operation The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The chassis tubes are steel with a corrosion resistant coating applied to the external surfaces and the flex hoses are made of reinforced rubber. The rubber flex hoses allow for the movement of the vehicle's suspension. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4295 Brake Hose/Line: Testing and Inspection Flexible rubber hose is used at both front brakes and at the rear axle. Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. The steel brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. The flexible brake tube sections used on this vehicle in the primary and secondary tubes from the master cylinder to the ABS hydraulic control unit connections, and the chassis brake tubes between the hydraulic control unit and the proportioning valve must also be inspected. This flexible tubing must be inspected for kinks, fraying and its contact with other components of the vehicle or contact with the body of the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring Brake Hose/Line: Service and Repair Brake Tubing Repair/Tube Flaring General Information CAUTION: When repairing brake chassis lines or flex hoses, the correct fasteners must be used to attach the routing clips or hoses to the front suspension cradle. The fasteners used to attach components to the front suspension cradle have an anti-corrosion coating due to the suspension cradle being made of aluminum. Only Mopar replacement fasteners with the required anti-corrosion coating are to be used if a replacement fastener is required when installing a brake chassis line or flex hose. Only double wall 4.75 mm (3/16 inches) steel tubing with Al-rich/ZW-AC alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube. NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes between the master cylinder and the hydraulic control unit are 6 mm (15/64 inches). These tubes are also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same anti-corrosion coating. Be sure the correct tube nuts are used for the replacement of these hydraulic brake tubes. Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. If the primary or secondary brake line from the master cylinder to the ABS Hydraulic Control Unit, or the flexible brake lines between the hydraulic control unit and the proportioning valve require replacement only the original factory brake lines containing a flexible section can be used. This is required due to the movement of the front suspension cradle while the vehicle is in motion. Cutting And Flaring Of Brake Fluid Tubing Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4298 Tube End Properly Prepared For Flaring Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing. Ream out any burrs or rough edges showing on inside of tubing. This will make the ends of tubing square and ensure better seating of flared end tubing. Place tube nut on tubing before flaring the tubing. Double Inverted Tubing Flares Inverted Flare And ISO Flare Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4299 Inverted Double Wall Flare And ISO Flare Tubing Connections To make a double inverted tubing flare. Open handles of Flaring Tool, Special Tool C-4047 or equivalent. Rotate jaws of tool until the mating jaws of tubing size are centered between vertical posts on tool. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place. Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring tool and lock tubing in place. Place 3/16 inch plug of gauge (A) down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove tubing from flaring tool and inspect seat. Replace any damaged tube routing clips. ISO Tubing Flares CAUTION: All ISO style tubing flares and are of metric dimensions. When performing any service procedures on vehicles using ISO style tubing flares, metric size tubing of 4.75 mm MUST be used with metric ISO tube flaring equipment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4300 To create a (metric) ISO style tubing flare, Use Snap-On Flaring Tool TFM-428, or equivalent. See and proceed with the steps listed below. Be sure to place the tubing nut on the tube before flaring the tubing. 1. Carefully prepare the end of the tubing to be flared. Be sure the end of the tubing to be flared is square and all burrs on the inside of the tubing are removed. This preparation is essential to obtain the correct form of a (metric) ISO tubing flare. 2. Open jaws of the Flaring Tool. Align the mating size jaws of the flaring tool around the size of the tubing to be flared. Close the jaws of the Flaring Tool around the tubing to keep it from sliding out of the flaring tool, but do not lock the tubing in place. 3. Position the tubing in the jaws of the Flaring Tool so that it is flush with the top surface of the flaring tool bar assembly. 4. Install the correct size adapter for the brake tubing being flared, on the feed screw of the yoke assembly. Center the yoke and adapter over the end of the tubing. Apply lubricant to the adapter area that contacts brake tubing. Making sure the adapter pilot is fully inserted in the end of the brake tubing. Screw in the feed screw of the yoke assembly until the adapter has seated squarely on the surface of the bar assembly. This process has created the (metric) ISO tubing flare. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4301 Brake Hose/Line: Service and Repair Brake Tubing/Hose Replacement CAUTION: When installing brake chassis lines or flex hoses on the vehicle, the correct fasteners must be used to attach the routing clips or hoses to the front suspension cradle. The fasteners used to attach components to the front suspension cradle have an anti-corrosion coating due to the suspension cradle being made of aluminum. Only Mopar replacement fasteners with the required anti-corrosion coating are to be used if a replacement fastener is required when installing a brake chassis line or flex hose. Only double wall 4.75mm (3/16 inches) steel tubing with Al-rich/ZW-AC alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube. NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes between the master cylinder and the hydraulic control unit are 6 mm (15/64 inches). These tubes are also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same anti-corrosion coating. Be sure that the correct tube nuts are used for the replacement of these hydraulic brake tubes. Care should be taken when replacing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. If the primary or secondary brake tube from the master cylinder to the ABS Hydraulic Control Unit (HCU) or the brake tubes from the HCU to the proportioning valve require replacement, only the original factory brake line containing the flexible section can be used as the replacement part. This is required due to cradle movement while the vehicle is in motion. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes Brake Proportioning/Combination Valve: Specifications With Antilock Brakes To Frame Rail Attaching Bolts ............................................................................................................................................................ 14 Nm (125 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes > Page 4306 Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes To Mounting Bracket Attaching Bolts ................................................................................................................................................ 23 Nm (200 inch lbs.) Actuator Assembly Adjustment Nut ........................................................................................................................................................ 5 Nm (45 inch lbs.) Mounting Bracket To Frame Rail Bolts .............................................................................................................................................. 17 Nm (150 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Fixed Proportioning Valve Brake Proportioning/Combination Valve: Description and Operation Fixed Proportioning Valve The hydraulic brake system on all vehicles is diagonally split. This means that the left front and right rear brakes are on one hydraulic circuit with the right front and left rear brakes on the other hydraulic circuit. On vehicles equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is mounted to the front suspension crossmember on the driver's side of the vehicle. The (HCU) acts as the hydraulic system junction block, diagonally splitting the brakes hydraulic system. Fixed Proportioning Valve Location All vehicles equipped with ABS brakes use 2 fixed proportioning valves. The fixed proportioning valves are mounted in a common bracket on the left frame rail at the rear of the vehicle. FIXED PROPORTIONING VALVE OPERATION The fixed proportioning valve is made out of aluminum and has an integral mounting bracket. The fixed proportioning valve is non-serviceable component and must be replaced as an assembly if found to be functioning improperly. The fixed proportioning valve is mounted to the bottom of the left rear frame rail, just forward of the rear shock absorber to frame rail mounting location. The proportioning valve has 2 inlet ports for brake fluid coming from the ABS modulator, and 2 outlet ports for brake fluid going to the rear wheel brakes. The fixed proportioning valve operates by allowing full hydraulic pressure to the rear brakes up to a set point, called the valve's split point. Beyond this split point the proportioning valve reduces the amount of hydraulic pressure to the rear brakes according to a certain ratio. Thus, on light brake pedal applications the proportioning valve allows approximately equal brake hydraulic pressure to be supplied to both the front and rear brakes. On heavier brake pedal applications though, the proportioning valve will control hydraulic pressure to the rear brakes, so that hydraulic pressure at the rear brakes will be lower than that at the front brakes. This controlled hydraulic pressure to the rear brakes prevents excessive rear wheel ABS cycling during moderate stops. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 4309 Brake Proportioning/Combination Valve: Description and Operation Height Sensing Proportioning Valve CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inappropriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. Junction Block Location On vehicles not equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is replaced by a junction block. The junction block is made of aluminum and is mounted to the front suspension crossmember on the driver's side of the vehicle in the same location as the (HCU) on an ABS equipped vehicle. The junction block is permanently attached to its mounting bracket and must be replaced as an assembly with its mounting bracket. The junction block is used for diagonally splitting the brake's hydraulic system. Height Sensing Proportioning Valve Vehicles not equipped with ABS brakes use a height sensing proportioning valve. The height sensing proportioning valve is mounted on the left frame rail at the rear of the vehicle. The height sensing proportioning valve uses an actuator assembly to attach the proportioning valve to the left rear spring for sensing changes in vehicle height. HEIGHT SENSING PROPORTIONING VALVE OPERATION The height sensing proportioning valve regulates the hydraulic pressure to the rear brakes. The proportioning valve regulates the pressure by sensing the load condition of the vehicle through the movement of the proportioning valve actuator assembly. The actuator assembly is mounted between the height sensing proportioning valve and the actuator bracket on the left rear leaf spring. As the rear height of the vehicle changes depending on the load the vehicle is carrying the height change is transferred to the height sensing proportioning valve. This change in vehicle height is transferred through the movement of the left rear leaf spring. As the position of the left rear leaf spring changes this movement is transferred through the actuator bracket to the actuator assembly and then to the proportioning valve. Thus, the height sensing proportioning valve allows the brake system to maintain the optimal front to rear brake balance regardless of the vehicle load condition. Under a light load condition, hydraulic pressure to the rear brakes is minimized. As the load condition of the vehicle increases, so does the hydraulic pressure to the rear brakes. The proportioning valve section of the valve operates by transmitting full input hydraulic pressure to the rear brakes up to a certain point, called the split point. Beyond the split point the proportioning valve reduces the amount of hydraulic pressure to the rear brakes according to a certain ratio. Thus, on light brake applications, approximately equal hydraulic pressure will be transmitted to the front and rear brakes. At heavier brake Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 4310 applications, the hydraulic pressure transmitted to the rear brakes will be lower then the front brakes. This will prevent premature rear wheel lock-up and skid. The height sensing section of the valve thus changes the split point of the proportioning valve, based on the rear suspension height of the vehicle. When the height of the rear suspension is low, the proportioning valve interprets this as extra load and the split point of the proportioning valve is raised to allow more rear braking. When the height of the rear suspension is high, the proportioning valve interprets this as a lightly loaded vehicle and the split point of the proportioning valve is lowered and rear braking is reduced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 4311 Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve Proportioning Valve There are two proportioning valves used in the antilock brake system. One valve controls each rear braking circuit, but both are serviced as one assembly. Both proportioning valves are mounted together on a bracket that is attached to the left frame rail near the left rear shock absorber. The ABS proportioning valves function the same as standard proportioning valves. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > With Antilock Brakes Brake Proportioning/Combination Valve: Testing and Inspection With Antilock Brakes A vehicle equipped with ABS uses a fixed proportioning valve. On a vehicle equipped with ABS, premature or excessive rear wheel ABS cycling may be an indication that the brake fluid pressure to the rear brakes is above the desired output. Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining material specification. The vehicles brake system is not balanced for after market brake shoe assembly lining material. If brake shoe assembly lining material is of satisfactory condition, and of the correct material specification, check for proper proportioning valve function using the following procedure: Rear Brake Proportioning Valve And Brake Tube Locations 1. Road test vehicle to be sure the vehicle is truly exhibiting a condition of excessive rear wheel ABS cycling. Since ABS cycles both rear brakes together both proportioning valves of the assembly must be tested. Use the following procedure to test the proportioning valve: 2. Remove one of the chassis brake lines coming from the ABS modulator, at the proportioning valve assembly. Remove the hydraulic brake line going to one of the rear wheels of the vehicle from the proportioning valve. 3. Remove the 2 bolts attaching the proportioning valve to the frame rail. CAUTION: When lowering the proportioning valve, care must be taken not to kink any of the chassis brake lines. 4. Carefully lower the proportioning valve for clearance to install the proportioning valve test fittings. Proportioning Valve Test Fitting Installation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4314 5. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the inlet port of the proportioning valve assembly, from which the chassis brake line was removed. Install the removed chassis brake line into the Pressure Test Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required outlet port of the proportioning valve. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required outlet port of the proportioning valve. Then install the removed chassis brake line into the Pressure Test Fitting. Pressure Gauges Installed On Pressure Test Fittings 6. Install a pressure gauge from Gauge Set, Special Tool C-4007-A into each pressure test fitting. Bleed air out of hose from pressure test fittings to pressure gauges, at the pressure gauges. Then bleed air out of the brake line being tested, at that rear wheel cylinder. 7. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000 psi) is obtained on the proportioning valve inlet gauge. Then based on the type of brake system the vehicle is equipped with and the pressure specification shown on the following table, compare the pressure reading on the outlet gauge to the specification. If outlet pressure at the proportioning valve is not within specification when required inlet pressure is obtained, replace the proportioning valve. 8. Repeat steps 2 through 7 for the other proportioning valve of the assembly. CAUTION: When mounting the original or a replacement proportion valve on the frame rail of the vehicle install the mounting bolts in only the two forward holes of the mounting bracket. Proportioning valve split point pressure conversion is 1 bar is equal to 14.5 psi. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4315 Brake Proportioning/Combination Valve: Testing and Inspection Without Antilock Brakes CAUTION: The use of aftermarket load leveling or load capacity increasing devices on this vehicle are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inappropriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. When a premature rear wheel skid is obtained on a brake application, it may be an indication that the hydraulic pressure to the rear brakes is above the specified output from the proportioning valve. This condition indicates a possible malfunction of the height sensing proportioning valve, which will require testing to verify that it is properly controlling the hydraulic pressure allowed to the rear brakes. Premature rear wheel skid may also be caused by an incorrectly adjusted proportioning valve actuator assembly, or contaminated front or rear brake linings. Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining material specification. The vehicles brake system is not balanced for after market brake shoe assembly lining material. If both front and rear brakes check OK, proceed to verify that the actuator assembly for the height sensing proportioning valve is adjusted correctly. If the proportioning valve is adjusted correctly, proceed with the test procedure for the height sensing proportioning valve as follows: Actuator Assembly Adjustment Nut 1. Remove the actuator assembly adjustment nut. Remove the actuator assembly from the lever on the height sensing proportioning valve. Brake Tube Connections To Proportioning Valve 2. Remove the chassis brake tube coming from the junction block from the front of the height sensing proportioning valve. Remove the chassis brake tube going to the rear brakes from the back of the height sensing proportioning valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4316 Proportioning Valve Test Fitting Installation Pressure Gauges Installed On Pressure Test Fittings 3. Install the required fittings from Pressure Test Fittings, Special Tool 6833 into the inlet port of the proportioning valve assembly, from which the chassis brake line was removed. Install the removed chassis brake line into the Pressure Test Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required outlet port of the proportioning valve. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required outlet port of the proportioning valve. Then install the removed chassis brake line into the Pressure Test Fitting. 4. Install a pressure gauge from Gauge Set, Special Tool C-4007-A into each pressure test fitting. Bleed air out of hose from pressure test fittings to pressure gauges, at the pressure gauges. Then bleed air out of the brake line being tested, at that rear wheel cylinder. 5. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000 psi) is obtained on the proportioning valve inlet gauge. Then based on the type of brake system the vehicle is equipped with and the pressure specification shown on the following table, compare the pressure reading on the outlet gauge to the specification. If outlet pressure at the proportioning valve is not within specification when required inlet pressure is obtained, replace the proportioning valve. 6. Remove the pressure test fittings and pressure pauses from the proportioning valve. 7. Install the chassis brake lines in the correct ports of the proportioning valve. 8. Install the pressure test fittings and pressure gauges in the opposite inlet and outlet port of the height sensing proportioning valve. Repeat steps 4 and 5 for the other proportioning valve. 9. Remove the pressure test fittings and pressure gauges from the proportioning valve. 10. Install the chassis brake lines in the correct ports of the proportioning valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4317 11. Install the actuator on the height sensing proportioning valve. Adjust the proportioning valve actuator. 12. Bleed both rear hydraulic circuits at the rear brakes. 13. Road test vehicle. Proportioning valve split point pressure conversion is 1 bar is equal to 14.5 psi. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes Brake Proportioning/Combination Valve: Service and Repair With Antilock Brakes The actual proportioning valves of the proportioning valve assembly are not serviceable or replaceable. If a proportioning valve of the proportioning valve assembly is not functioning properly, the fixed proportioning valve must be replaced as an assembly. REMOVE 1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve. 2. Raise vehicle on jackstands or centered on a hoist. CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. Chassis Brake Tubes At Proportioning Valve 3. Remove the 4 chassis brake lines from the inlet and outlet ports of the proportioning valve. Proportioning Valve Attachment To Vehicle 4. Remove the bolts attaching the proportioning valve bracket to the frame rail of the vehicle. Remove the fixed proportioning valve assembly from the vehicle. INSTALL CAUTION: When mounting the original or a replacement proportioning valve on the frame rail of the vehicle install the mounting bolts in only the two forward holes of the mounting bracket. 1. Install proportioning valve assembly on the frame rail of the vehicle. Install the proportioning valve assembly attaching bolts. Tighten the attaching bolts to a torque of 14 Nm (125 inch lbs.). 2. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve assembly. Tighten all 4 line nuts to a torque of 16 Nm (142 inch lbs.). 3. Bleed the brake system thoroughly enough to ensure that all air has been expelled from the hydraulic system. See Brake Bleeding for the proper bleeding procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4320 4. Lower the vehicle to the ground. 5. Road test the vehicle to verify proper operation of the vehicle's brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4321 Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes The components of the proportioning valve assembly are not serviceable or replaceable. If a component of the proportioning valve assembly is not functioning properly, the proportioning valve must be replaced as an assembly. REMOVAL 1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve. 2. Raise vehicle on jackstands or centered on a hoist. CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. Chassis Brake Tubes At Proportioning Valve 3. Remove the 4 chassis brake tubes from the inlet and outlet ports of the proportioning valve. Proportioning Valve Mounting 4. Remove the 2 bolts attaching the proportioning valve to the proportioning valve mounting bracket. Remove the proportioning valve from the mounting bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4322 Actuator Attachment To Proportioning Valve 5. Remove the hooked end of the proportioning valve actuator from the isolator bushing on the lever of the height proportioning valve. INSTALLATION 1. Install the hooked end of the actuator on the proportioning valve lever. Be sure isolator bushing on lever of proportioning valve is fully seated in hook of actuator. NOTE: When installing height sensing proportioning valve on mounting bracket be sure proportioning valve shield is installed between the proportioning valve and the mounting bracket. 2. Install height sensing proportioning valve on mounting bracket. Install the proportioning valve attaching bolts. Tighten the attaching bolts to a torque of 23 Nm (200 inch lbs.). 3. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve. Tighten all 4 line nuts to a torque of 16 Nm (142 inch lbs.). 4. Adjust the proportioning valve actuator. 5. Bleed the brake system thoroughly to ensure that all air has been expelled from the hydraulic system. See Brake Bleeding for the proper bleeding procedure. 6. Lower the vehicle to the ground. 7. Road test the vehicle to verify proper operation of the vehicles brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Mounting Bracket To Suspension Cradle Bolts .................................................................................................................................. 28 Nm (250 inch lbs.) To Mounting Bracket Isolator Attaching Bolts ..................................................................................................................................... 11 Nm (97 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4326 Hydraulic Control Unit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4327 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Teves Mark 20 ICU The Hydraulic Control Unit (HCU) is mounted to the CAB as part of the ICU. The ICU is located on the driver's side of the front suspension cradle under the vehicle. The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is approximately 1 inch longer on the low pressure fluid accumulators side than a HCU on a vehicle that is equipped with only ABS. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. On vehicles with traction control, there is an extra set of valves and solenoids. The ASR valves, mounted in the HCU valve block, are normally in the open position and close only when the traction control is applied. These isolator valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is being applied. The rear brakes need to be isolated from the master cylinder when traction control is being applied so the rear wheels do not drag. For more information, see Traction Control System. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU-one for the primary hydraulic circuit and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 5 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. On ABS-only vehicles, there is a mini-accumulator on the secondary hydraulic circuit that protects the master cylinder seals during an ABS stop, and there is a noise dampening chamber on the primary circuit. On ABS with traction control vehicles, there are two noise dampening chambers in the HCU. PUMP/MOTOR There are two pump assemblies in the HCU-one for the primary hydraulic circuit and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the CAB. The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, one piston draws fluid from the accumulators, and the opposing piston pumps fluid to the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The CAB may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4328 after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Replacement Removal NOTE: Before proceeding, review all SERVICE WARNINGS AND CAUTIONS in Service Precautions. 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the HCU. 3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. CAB 25 Way Connector 4. Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. Unlocked 25 Way CAB Connector 5. Remove the 25 way connector from the CAB. The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will raise and unlock the 25 way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. 6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4331 Brake Tube Connections To HCU 7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. ICU To Suspension Cradle Mounting Bolts 8. Remove the 3 bolts attaching the ICU mounting bracket to the front suspension crossmember. 9. Remove ICU and the mounting bracket as a unit from the vehicle. ICU Mounting Bolts 10. Remove the 3 bolts mounting the ICU to the mounting bracket. Separate the ICU from the mounting bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4332 11. Refer to Overhaul for the procedure on separating and attaching the CAB to the HCU. Installation 1. Install the ICU on the mounting bracket. Install the 3 bolts attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front suspension crossmember. 2. Install the ICU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the ICU bracket to the crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). Brake Tube Connections To HCU CAUTION: ^ Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. ^ When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to the image for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the ICU mounting bracket. 3. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. 4. Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle. 5. Clip the cab wiring harness to the ICU mounting bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4333 Brake Tube Routing Clips 6. Install the routing clips on the brake tubes. 7. Lower the vehicle. 8. Connect negative cable back on negative post of the battery. 9. Bleed the base and ABS hydraulic systems. 10. Road test vehicle to ensure proper operation of the base and antilock brake systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4334 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Overhaul REMOVAL NOTE: To replace the Hydraulic Control Unit (HCU) or the Controller Antilock Brake (CAB) on this vehicle, the entire Integrated Control Unit (ICU) needs to be removed from the vehicle. The CAB can then be separated from the HCU. Do not attempt to replace the CAB with the ICU mounted in the vehicle. 1. Remove the ICU from the vehicle. Pump/Motor To CAB Wiring Harness 2. Disconnect the pump/motor wiring harness from the CAB. CAB Attaching Bolts 3. Remove the 4 bolts attaching the CAB to the HCU. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4335 Remove/Install CAB 4. Remove the CAB from the HCU. INSTALLATION 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle. 5. Bleed the base and ABS hydraulic systems. 6. Road test the vehicle to ensure proper operation of the base brakes and ABS. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Specifications Hydraulic System Junction Block: Specifications Junction Block Mounting Bolts ........................................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Adjustments Load Compensator: Adjustments PROPORTIONING VALVE (HEIGHT SENSING) Proportioning valve adjustment will be required if there is a complaint of premature rear wheel lockup and the front and rear brake shoe linings checked OK during inspection, the height sensing proportioning valve required replacement, or there is a complaint of excessive pedal effort and the vacuum booster and brake pedal checked OK. Make sure the proportioning valve and the mounting bracket are firmly attached to the vehicle. Then, proceed with the following procedure to perform the adjustment of the vehicle. 1. Raise vehicle. Vehicle is to be raised and supported on jackstands or with a frame contact type hoist so the rear suspension of the vehicle is hanging free. 2. Remove rear wheels/tires. 3. Using an appropriate jack, support the rear axle prior to the removal of the track bar and shock absorber bolts from the rear axle. 4. Unbolt the track bar from the rear axle. 5. Unbolt both shock absorbers from the rear axle. 6. Loosen (do not remove) both of the leaf spring to front spring hanger pivot bolts. NOTE: When lowering the rear axle be sure that the leaf springs do not come in contact with the hoist limiting the downward movement of the axle. If this occurs an improper adjustment of the actuator may result. 7. Lower the rear axle so it is at its farthest point of downward movement. 8. Loosen the adjustment nut on the actuator. 9. Be sure the hooked end of the actuator is correctly (fully) seated in the clip on the proportioning valve lever and that the clip is correctly positioned on the lever of the proportioning valve. 10. Pull the housing of the proportioning valve actuator toward the spring hanger until the lever on the proportioning valve bottoms on the body of the proportioning valve. Hold the proportioning valve actuator in this position while tightening the adjustment nut to a torque of 5 Nm (45 inch lbs.). Proportioning valve adjustment is now complete. 11. Install shock absorbers and track bar on rear axle. Do not tighten the mounting bolts of the loosened suspension components at this time. 12. Install the wheel/tires. 13. Lower the vehicle to the ground. Be sure that the suspension is supporting the full weight of the vehicle. 14. Tighten the spring to front hanger pivot bolts to a torque of 156 Nm (115 ft. lbs.). 15. Tighten the shock absorber mounting bolts to a torque of 101 Nm (75 ft. lbs.). 16. Tighten the track bar mounting bolt to a torque of 95 Nm (70 ft. lbs.). 17. Road test vehicle to ensure that the premature rear wheel lockup condition has been corrected. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes Brake Master Cylinder: Specifications With Antilock Brakes DIMENSIONS: Bore/Stroke .................................................................................................................................................... 23.8 mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ................................................................... ................................................................................................................................. 50/50 With ABS Only: Primary Fluid Outlet Ports .......................................................................................... ........................................................................................... 7/16-24 Secondary Fluid Outlet Ports ..... .............................................................................................................................................................. .............. 7/16-24 With ABS With Traction Control: Primary Fluid Outlet Ports ............................................................... ..................................................................................................................... M12 x 1 Secondary Fluid Outlet Ports .......................................................................................................................................... ...................................... M12 x 1 TIGHTENING TORQUES: Mounting Nuts ..................................................................................................................................... ............................................ 25 Nm (225 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes > Page 4346 Brake Master Cylinder: Specifications Without Antilock Brakes DIMENSIONS: Bore/Stroke .................................................................................................................................................... 23.8 mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ................................................................... ................................................................................................................................. 50/50 Primary Fluid Outlet Ports ................................................................................................................................. .................................................... 7/16-24 Secondary Fluid Outlet Ports ............................................ ..................................................................................................................................... 7/16-24 TIGHTENING TORQUES: Mounting Nuts ..................................................................................................................................... ............................................ 25 Nm (225 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4347 Brake Master Cylinder: Description and Operation Master Cylinder Assembly The master cylinder consists of the following components: The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and threaded ports with seats for the hydraulic brake line connections. The brake fluid reservoir of the master cylinder assembly is made of a see through polypropylene type plastic. A low fluid switch is also part of the reservoir assembly. This vehicle uses 3 different master cylinders. Master cylinder usage depends on what type of brake system the vehicle is equipped with. If a vehicle is not equipped with antilock brakes, or is equipped with antilock brakes without traction control, a conventional compensating port master cylinder is used. If a vehicle is equipped with antilock brakes with traction control, a dual center port master cylinder is used. The third master cylinder used on this vehicle is unique to vehicles equipped with four wheel disc brakes. The master cylinder used for this brake application has a different bore diameter and stroke than the master cylinder used for the other available brake applications. The master cylinders used on front wheel drive applications (non four wheel disc brake vehicles) have a master cylinder piston bore diameter of 23.8 mm. The master cylinder used on the all wheel drive applications (four wheel disc brake vehicles) have a master cylinder piston bore diameter of 25.4 mm. When replacing a master cylinder, be sure to use the correct master cylinder for the type of brake system the vehicle is equipped with. The master cylinder is not a repairable component and must be replaced if diagnosed to be functioning improperly. CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface from the bore. The master cylinder primary outlet port supplies hydraulic pressure to the right front and left rear brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Bench Bleeding CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange, do not clamp on primary piston, seal, or body of master cylinder. Master Cylinder Mounted In Vise 1. Clamp the master cylinder in a vise using only the mounting flange. NOTE: Two different size bleeding tubes are used depending on which type of master cylinder the vehicle is equipped with. Vehicles equipped with traction control use a center port master cylinder with a 6 millimeter diameter brake tube. Vehicles not equipped with traction control use a compensating port master cylinder using a standard 3/16 inch diameter brake tube. Be sure the correct size bleeding tubes are used when bleeding the master cylinder. Bleed Tubes Installed On Master Cylinder 2. Install the Bleeding Tubes, Special Tool 6920, for a non-traction control master cylinder or Special Tool 8129 for a traction control master cylinder on the master cylinder. Position bleeding tubes so the outlets of bleeding tubes will be below surface of brake fluid when reservoir is filled to its proper level. 3. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled from master cylinder. 5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap from the master cylinder filler neck, on the master cylinder fluid reservoir. 8. Install the master cylinder assembly on the power brake vacuum booster. NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master cylinder, but the base brake hydraulic Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4350 system must be bled to ensure no air is entered the hydraulic system when the master cylinder was removed. Manual Bleeding NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. - To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the rear brakes. - The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. ^ Left Rear Wheel ^ Right Front Wheel ^ Right Rear Wheel ^ Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4351 Brake Master Cylinder: Service and Repair Master Cylinder Replacement CAUTION: Different types of master cylinders are used on this vehicle. Vehicles equipped with traction control use a center port master cylinder. Vehicles not equipped with traction control use a compensating port master cylinder. Be sure to verify if the vehicle is equipped with traction control and that the correct replacement master cylinder is used. Also, vehicles that are equipped with four wheel disc brakes have a master with a different size piston bore than the other master cylinders. If a new master cylinder is being installed, be sure the correct master cylinder is used for the type of brake system the vehicle is equipped with. REMOVE CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). CAUTION: Before removing the master cylinder filler tube from the brake fluid reservoir, the filler tube, brake fluid reservoir and master cylinder must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the brake fluid reservoir and entering the brakes hydraulic system. 2. Thoroughly clean all surfaces of the filler neck, brake fluid reservoir, and master cylinder. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Filler Tube Removal 3. Remove master cylinder filler tube from brake fluid reservoir by pushing down and rotating. Then remove the cap from the removed filler tube and install it on the master cylinder reservoir. Master Cylinder Assembly 4. Remove vehicle wiring harness connector, from the brake fluid level sensor, in master cylinder brake fluid reservoir. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4352 Primary/Secondary Brake Tubes At Master Cylinder 5. Disconnect the primary and secondary brake tubes from the master cylinder housing. Install sealing plugs in the open brake tube outlets on master cylinder assembly. CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the lower brake vacuum booster. 6. Clean the area where the master cylinder assembly attaches to the power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Mounting To Vacuum Booster 7. Remove the 2 nuts attaching the master cylinder assembly to the brake vacuum booster. 8. Slide master cylinder assembly straight out of the power brake vacuum booster. CAUTION: The master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal/boot on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. 9. Remove the vacuum seal located on the mounting flange of the master cylinder. The vacuum seal is removed from the master cylinder by carefully pulling it away from the master cylinder. Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and master cylinder casting. Bleeding Master Cylinder CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange, do not clamp on primary piston, seal or body of master cylinder. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4353 Master Cylinder Mounted In Vise 1. Clamp the master cylinder in a vise using only the mounting flange. NOTE: Two different size bleeding tubes are used depending on which type of master cylinder the vehicle is equipped with. Vehicles equipped with traction control use a center port master cylinder with a larger diameter brake tube. Vehicles not equipped with traction control use a compensating port master cylinder using a standard 3/16 inch diameter brake tube. Be sure the correct size bleeding tubes are used when bleeding the master cylinder. Bleed Tubes Installed On Master Cylinder 2. Install the Bleeding Tubes, Special Tool 6920 for a non-traction control master cylinder or Special Wool 8129 for a traction control master cylinder on the master cylinder. Position bleeding tubes so the outlets of bleeding tubes will be below surface of brake fluid when reservoir is filled to its proper level. 3. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an Equivalent. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled from master cylinder. 5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master cylinder. But, the base brake hydraulic system must be bled to ensure no air is entered the hydraulic system when the master cylinder was removed. INSTALL CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. Use only procedure detailed below for installing the vacuum seal onto the master cylinder. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4354 Vacuum Seal Installed On Master Cylinder 1. Install a NEW vacuum seal on master cylinder making sure seal sits squarely in groove of master cylinder casting. 2. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. 3. Install the 2 master cylinder to power brake unit mounting nuts. Then tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). CAUTION: When installing the primary and secondary brake tubes on master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS hydraulic control module (HCU) and the master cylinder, when the vehicle is in motion. 4. Connect the primary and secondary brake tubes to master cylinder primary and secondary ports. Brake tubes must be held securely when tightened to control orientation of flex section. Then fully tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). 5. Install the vehicle wiring harness connector, on the brake fluid level sensor in the master cylinder brake fluid reservoir. 6. Install filler tube into the master cylinder fluid reservoir. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4355 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement 1. Clean master cylinder housing and brake fluid reservoir. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. 2. Remove the filler tube and brake fluid reservoir cap. Using a syringe or equivalent type tool empty as much brake fluid as possible from the reservoir. CAUTION: When removing fluid reservoir from the master cylinder, do not pry off using any type of tool. This can damage the fluid reservoir or master cylinder housing. 3. Remove the master cylinder assembly from the power brake vacuum booster. Master Cylinder Mounted In Vise 4. Mount the master cylinder in a vise using the master cylinder mounting flange. Fluid Reservoir Retaining Pins 5. Using correct size pin punch, remove the 2 retaining pins between the fluid reservoir and master cylinder housing. Rock the brake fluid reservoir from side to side while pulling up to remove it from the seal grommets in master cylinder housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4356 Master Cylinder To Fluid Reservoir Seal Grommets 6. Remove the 2 master cylinder housing to brake fluid reservoir seal grommets. 7. Install new master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing. 8. Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over sealing grommets. Seat reservoir into sealing grommets using a rocking motion while firmly pressing down on fluid reservoir. 9. Be sure fluid reservoir is positioned properly on master cylinder. Bottom of fluid reservoir is to be touching the top of both sealing grommets when properly installed on master cylinder housing. 10. Install the 2 fluid reservoir to master cylinder retaining pins. 11. Install the master cylinder assembly on the power brake vacuum booster. 12. Install filler tube on the fluid reservoir. Fill fluid reservoir to its proper level as indicated on the outboard side of the fluid reservoir. Be careful not to overfill the fluid reservoir, fluid is not intended to be stored in the filler tube. Install cap on fluid reservoir filler tube. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4357 Brake Master Cylinder: Service and Repair Fluid Reservoir Fill Tube Replacement The master cylinder fluid reservoir filler neck is removable from the master cylinder fluid reservoir. The filler neck if required, can be replaced as a separate component of the fluid reservoir. The filler neck is removed and installed using the following procedure. REMOVE 1. Check brake fluid level in master cylinder fluid reservoir to be sure brake fluid is not in the filler neck. If brake fluid is in filler neck, lower fluid level before removing filler neck from fluid reservoir. Master Cylinder Fluid Reservoir Filler Neck 2. Grasp filler neck at cap end and push straight down. This will cause the filler neck to pop out of the fluid reservoir. INSTALL 1. Wet the O-ring on the reservoir end of the filler neck with fresh clean brake fluid. 2. Position the filler neck in the opening on the fluid reservoir. Ensure tab on filler neck is in the groove on the front of the fluid reservoir. 3. Push down while slightly rocking filler neck until filler neck snaps into the fluid reservoir opening. 4. Install cap on filler neck. 5. Check and/or add brake fluid in reservoir to ensure it is at the correct level. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4358 Brake Master Cylinder: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal 1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master cylinder push rod. Vacuum Seal Installed On Master Cylinder 4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When installing new vacuum seal, be sure it is squarely seated against master cylinder mounting flange and in groove of push rod. 5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6. Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to ensure proper operation of the vehicle's power brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Diameter 3/4 in To Support Plate Mounting Bolts 75 in.lb Bleeder Screw 80 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE 1. In case of a leak, remove brake shoes. Replace if soaked with grease or brake fluid. 2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel cylinder attaching bolts. Pull wheel cylinder assembly off the brake support plate. INSTALL 1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4364 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected, and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4365 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: Fig 3 Wheel Cylinder 1. Pry boots away from cylinders and remove. 2. Press in on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol, (DO NOT USE ANY PETROLEUM BASE SOLVENTS) clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.) 4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLE Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with only Mopar Protect A-Cup Lubricant. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Technical Service Bulletins > Rear Wheel Park Brake Actuator/Lever - Service Parking Brake Actuator: Technical Service Bulletins Rear Wheel Park Brake Actuator/Lever Service NUMBER: 05-09-99 GROUP: Brakes DATE: Nov. 5, 1999 SUBJECT: Rear Wheel Park Brake Actuator/Lever Service MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager 1997 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR WHEEL DISC BRAKES (SALES CODE BRE OR BR3). DISCUSSION: Whenever servicing the park brake actuator/lever of rear wheel disc brake equipped vehicles, DO NOT attempt to repair it. The park brake actuator/lever must be replaced with p/n 04882584AA whenever service is required. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: Adjustments The park brake cables on this vehicle have an automatic self adjuster built into the park brake pedal mechanism. When the foot operated park brake pedal is in its released (upward most) position, a clock spring automatically adjusts the park brake cables. The park brake cables are adjusted (tensioned) just enough to remove all the slack from the cables. The automatic adjuster system will not over adjust the cables causing rear brake drag. Due to the automatic adjust feature of the park brake pedal, adjustment of the parking brake cables on these vehicles relies on proper drum brake and park brake shoe adjustment. When the park brake pedal is applied the self adjuster is by-passed and the pedal operates normally to engage the park brakes. When a service procedure needs to be performed on the park brake pedal or the park brake cables, the automatic self adjuster can be manually locked out by the service technician. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement Parking Brake Cable: Service and Repair Front Cable Replacement REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. Parking Brake Cable Attachment To Equalizer 3. Remove the intermediate and left rear park brake cable from the park brake cable equalizer. Front Park Brake Cable Attachment To Body 4. Remove the front park cable housing retainer from body outrigger bracket. Cable is removable by sliding a 14 mm box wrench over cable retainer and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. 5. Lower vehicle. 6. Remove the left front door sill molding. 7. Remove the left front kick panel for access to the park brake cable and park brake pedal assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4376 Front Park Brake Cable At Floor Pan 8. Lift floor mat for access to park brake cable and floor pan. Pull the seal and the park brake cable out of the floor pan of vehicle. 9. Pull parking brake cable strand end forward and disconnect button from clevis. Tap cable housing end fitting out of pedal assembly bracket. 10. Remove cable retainer from the parking brake lever (pedal) assembly bracket. 11. Pull front parking brake cable assembly out of vehicle through hole in floor pan. INSTALLATION 1. Pass front parking brake cable assembly through hole in floor pan from the inside of the vehicle. 2. Pass cable strand button through the hole in the lever (pedal) assembly bracket. 3. Install cable retainer onto the park brake cable and then install cable retainer into pedal assembly bracket. 4. Install the end of the park brake cable into the retainer previously installed into the park brake pedal bracket. 5. Install cable strand button into the clevis on the park brake pedal mechanism. 6. Install the front park brake cable floor pan seal into hole in floor pan. Seal is to be installed so the flange on the seal is flush with the floor pan. Fold carpeting back down on floor. 7. Raise vehicle. 8. Insert brake cable and housing into body outrigger bracket making certain that housing retainer fingers lock the housing firmly into place. 9. Manually reset the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. 10. Assemble the park brake cables onto the park brake cable equalizer. 11. Lower vehicle and apply the park brake pedal 1 time. This will seat the parking brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4377 Parking Brake Cable: Service and Repair Intermediate Cable Replacement REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Manually lock out the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. Once the cable is released from the equalizer, do not remove the locking pliers until reinstallation of the cable is complete. Parking Brake Cable Attachment To Equalizer 3. Remove the intermediate parking brake cable from the parking brake cable equalizer. 4. Remove the locking nut securing the intermediate cable housing to the side bracket on the frame rail. Intermediate Cable Attachment To Right Rear Cable 5. Remove the intermediate parking brake cable from the cable connector attaching it to the right rear parking brake cable. Remove the locking nut securing the intermediate cable housing to the side bracket on the frame rail. 6. Remove the intermediate parking brake cable from the side brackets and vehicle. INSTALLATION 1. Install the ends of the park brake cables through the frame rails and into the side brackets. 2. Install the locking nuts at each end of the cable and securely tighten. 3. Install the intermediate parking brake cable on the cable connector at the right rear parking brake cable. 4. Install the intermediate park brake cable on the cable equalizer. 5. Remove the locking pliers from the front park brake cable. This will activate the automatic adjuster and correctly adjust the parking brake cables. 6. Install and position the foam collar on the parking brake cable to prevent it from rattling against the vehicle's floor. 7. Lower the vehicle and apply the park brake pedal 1 time, this will seat the park brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4378 Parking Brake Cable: Service and Repair Left Rear Cable Replacement REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3. Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. Locking Out Automatic Adjuster 4. Create slack in rear park brake cables by locking out the automatic adjuster as described here. Grasp an exposed section of front park brake cable near the equalizer and pull down on it. Then install a pair of locking pliers on the cable just rearward of the second body outrigger bracket. Parking Brake Cable Attachment To Equalizer 5. Disconnect the left rear parking brake cable from the parking brake cable equalizer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4379 Park Brake Cable Removal From Body Bracket 6. To remove parking brake cable housing from the body bracket, slide a 14 mm box end wrench over retainer end compressing the three fingers. Alternate method is to use an aircraft type hose clamp. 7. Remove the brake shoes from the brake support plate. 8. Disconnect parking brake cable from parking brake actuator lever. Removing Park Brake Cable From Brake Support Plate 9. Remove the parking brake cable housing retainer from the brake support plate using a 14 mm wrench to compress the retaining fingers. INSTALLATION 1. Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. 2. Attach the parking brake cable onto the park brake actuator lever. 3. Install the brake shoes on the rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect rear parking brake cable to the equalizer bracket. 6. Install brake drum, and wheel and tire assembly. 7. Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. 8. Apply and release park brake pedal 1 time. This will seat the park brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4380 Parking Brake Cable: Service and Repair Right Rear Cable Replacement REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3. Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. Locking Out Automatic Adjuster 4. Create slack in the rear parking brake cables by locking out the automatic adjuster as described here. Grasp an exposed section of front parking brake cable near the equalizer and pull down on it. At this time install a pair of locking pliers on the cable just rearward of the second body outrigger bracket. Intermediate Cable Attachment To Right Rear Cable 5. Disconnect the right rear parking brake cable from the connector on the intermediate cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4381 Right Park Brake Cable Removal From Body Bracket 6. To remove the right parking brake cable housing from the body bracket, slide a 14 mm box end wrench over the end of cable retainer to compress the retaining fingers. The alternate method using an aircraft type hose clamp will not work on the right side of the vehicle. 7. Remove the brake shoes from the brake support plate. 8. Disconnect parking brake cable from parking brake actuator lever. Removing Park Brake Cable From Brake Support Plate 9. Remove the parking brake cable housing retainer from the brake support plate using a 14mm wrench to compress the retaining fingers. Remove the cable. INSTALLATION 1. Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. 2. Attach the parking brake cable onto the parking brake actuator lever. 3. Install the brake shoes on the rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect the right rear parking brake cable to the connector on the intermediate parking brake cable. 6. Install the brake drum, then the wheel and tire assembly. 7. Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. 8. Lower the vehicle. 9. Apply and release park brake pedal 1 time. This will seat the park brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications Parking Brake Pedal: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 28 Nm (250 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications > Page 4385 Parking Brake Pedal: Service and Repair REMOVAL 1. Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. 2. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. 3. Remove sill scuff plate from left door sill. 4. Remove the left side kick panel. 5. Remove the steering column cover from the lower instrument panel. 6. Remove the reinforcement from the lower instrument panel. Parking Brake Cable Attachment To Equalizer 7. Remove the front parking brake cable from the parking brake cable equalizer. 8. Remove tension from front park brake cable. Tension is removed by releasing the locking pliers from the front park brake cable. 9. Remove the 3 bolts mounting the wiring junction block to the instrument panel. NOTE: When removing the lower mounting bolt, push the park brake pedal down 5 clicks to access the lower mounting bolt. 10. Remove the lower bolt mounting the park brake pedal to the body. 11. Remove the forward bolt mounting the park brake pedal to the body. 12. Remove the upper bolt mounting the park brake pedal to the body. Park Brake Pedal Mounting 13. Disconnect the electrical connector for the brake light switch. 14. Pull downward on front park brake cable while rotating park brake pedal mechanism out from behind junction block. 15. Remove park brake pedal release cable from park brake mechanism. 16. Remove the ground switch for the red brake warning lamp from the park brake pedal mechanism. 17. Remove front park brake cable button from park brake pedal mechanism. Tap end housing of front park brake cable out of park brake pedal mechanism. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications > Page 4386 INSTALLATION 1. Install the ground switch for the red BRAKE warning lamp on the park brake pedal mechanism 2. Install park brake cable end housing into park brake pedal mechanism. 3. Install cable retainer onto the park brake cable strand and then install retainer into pedal bracket. 4. Install cable strand button into the clevis on the park brake pedal mechanism. 5. Install wiring harness connector on red BRAKE warning lamp ground switch. 6. Install the park brake release cable on the release mechanism of the park brake pedal. 7. Position the park brake pedal mechanism into its installed position on the body of the vehicle. 8. Loosely install the top bolt mounting the park brake pedal mechanism to the body. 9. Loosely install the forward bolt mounting the park brake pedal mechanism to the body. 10. Loosely install the lower bolt mounting the park brake pedal mechanism to the body. 11. Tighten pedal mechanism attaching bolts to 28 Nm (250 inch lbs.). 12. Verify that the park brake pedal is in the fully released (full up) position. 13. Raise vehicle. 14. Install the front park brake cable on the park brake cable equalizer. NOTE: If the original lever assembly is being used, the lever mechanism auto adjuster spring tension will need to be reset. After the cable to equalizer bracket connection has been made, release the pliers, thus allowing the automatic adjuster to take set. 15. Lower vehicle. 16. Remove the lock-out pin (if a new lever has been installed) from the automatic cable adjuster on the park brake pedal mechanism. 17. Install the electrical junction block on the instrument panel. 18. Install the reinforcement on the lower instrument panel. 19. Install the steering column cover on the lower instrument panel. 20. Install the left side kick panel. 21. Install the sill scuff plate on the lower sill of the left door. 22. Install the negative (ground) cable on the battery. 23. Cycle the park brake pedal one time. This will seat the park brake cables and will allow the automatic self adjuster to properly tension the park brake cables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments PARKING BRAKE SHOES (WITH REAR DISC BRAKES) CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. Disc Brake Caliper 3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from hub/bearing. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. Measuring Park Brake Drum Diameter 5. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, accurately measure the inside diameter of the park brake drum portion of the rotor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4390 Reading Park Brake Drum Diameter 6. Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool. Setting Gauge To Park Brake Shoe Measurement 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to the reduced measurement. 8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on hub and bearing. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 13. Install disc brake caliper on caliper adapter. 14. Install wheel and tire. 15. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. 18. Road test the vehicle to ensure proper function of the vehicle's brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal Parking Brake Shoe: Service and Repair Removal On this vehicle, the park brake shoes are removed from the disc brake adapter removed from the vehicle. 1. Set the parking brake. The parking brake is set to keep the hub/bearing and axle shaft from rotating when loosening the hub nut. 2. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. 3. Remove the wheel/tire. Cotter Pin And Nut Retainer 4. Remove the cotter pin and nut retainer from the stub shaft of the outer C/V joint. Spring Washer 5. Remove the spring washer from the stub shaft of the outer C/V joint. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4393 Hub Nut and Washer 6. Remove the hub nut and washer from the stub shaft of the outer C/V joint. 7. Release the parking brake. Locking Out Automatic Adjuster 8. Create slack in the rear park brake cables by locking the out the automatic adjuster as described. Grasp the exposed section of front park brake cable and pull downward on it. Then install a pair of locking pliers on the front park brake cable just rearward of the second body outrigger bracket. Removing Caliper Guide Pin Bolts 9. Remove the disc brake caliper to adapter guide pin bolts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4394 Removing/Installing Caliper 10. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. Correctly Supported Caliper 11. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 12. Remove the rotor from the hub/bearing. Park Brake Cable Attachment To Actuator 13. Remove the horseshoe clip from the retainer on the end of the park brake cable. 14. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4395 Park Brake Cable Removal From Adapter 15. Remove the end of the park brake cable from the adapter. Park brake cable is removed from adapter using a 1/2 wrench slipped over the park brake cable retainer as show in to compress the locking tabs on the park brake cable retainer. Speed Sensor Attaching Bolt 16. Remove the attaching bolt from the wheel speed sensor. Then remove wheel speed sensor from hub/bearing and adapter. Hub/Bearing Mounting Bolts 17. Remove the hub/bearing to axle mounting bolts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4396 Hub/Bearing Removal And Installation 18. Remove the hub/bearing from the axle and the stub shaft of the outer C/V joint. 19. Remove the adapter from the rear axle. Adapter Mounted In Vise 20. Mount the adapter in a vise using the anchor boss for the park brake cable. Lower Return Spring 21. Remove the lower return spring from the leading and trailing park brake shoes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4397 Leading Brake Shoe Hold Down Pin And Spring 22. Remove the hold down spring and pin from the leading park brake shoe. Brake Shoe Adjuster 23. Remove the adjuster from the leading and trailing park brake shoe. Primary Brake Shoe Remove/Install 24. Remove the leading park brake shoe from the adapter. Leading brake shoe is removed by rotating the bottom of the brake shoe inward until the top of the brake shoe can be removed from the brake shoe anchor. Then remove the upper return springs from the leading brake shoe. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4398 Upper Return Springs 25. Remove the upper return springs from the trailing park brake shoe. Trailing Brake Shoe Hold Down Pin And Spring 26. Remove the hold down spring and pin from the trailing park brake shoe. 27. Remove the trailing park brake shoe from the adapter. 28. Remove the park brake shoe actuator from the adapter and inspect for signs of abnormal wear and binding at the pivot point. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4399 Parking Brake Shoe: Service and Repair Installation 1. Install the trailing brake shoe on the adapter. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. 2. Install the hold down spring and pin on the trailing park brake shoe. 3. Install the upper return springs on the trailing park brake shoe. 4. Install the upper return springs on the leading park brake shoe. Then position the top of the leading park brake shoe at the upper anchor and rotate the bottom of the shoe outward until correctly installed on the adapter. 5. Install the adjuster between the leading and trailing park brake shoe. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. 6. Install the hold down spring and pin on the leading park brake shoe. 7. Install the lower return spring on the leading and trailing park brake shoes. When installing the hold down spring it is to be installed behind the park brake shoes. 8. Install the 4 mounting bolts for the adapter and hub/bearing into the bolt holes in the axle. Adapter Installed On Mounting Bolts 9. Position the adapter on the 4 mounting bolts installed in the rear axle. 10. Install the hub/bearing on the stub shaft of outer C/V joint and into the end of the axle. 11. In a progressive cries-cross pattern, tighten the 4 hub/bearing mounting bolts until the hub/bearing is squarely seated against the axle. Then tighten the hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 12. Install the wheel speed sensor on the hub/ bearing and adapter. Install the wheel speed sensor attaching bolt. Tighten the wheel speed sensor attaching bolt to a torque of 12 Nm (105 in. lbs.). 13. Install the park brake cable into its mounting hole in the adapter. Be sure all the locking tabs on the park brake cable retainer are expanded out to ensure the cable will not pull out of the adapter. 14. Install the end of the park brake cable on the park brake actuator lever. NOTE: The horseshoe clip must be installed and installed properly when the park brake cable is installed in the adapter. The purpose of the horseshoe clip is to prevent park brake cable retainer from moving in the adapter. If horseshoe clip is not installed the park brake cable retainer will rattle in the adapter. 15. Install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip is installed between the retainer for the park brake cable and the adapter. Horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing toward the rear of the vehicle. 16. Remove the locking pliers from the front park brake cable. 17. Adjust the park brake drum-in-hat brake shoes. 18. Install the rotor on the hub/bearing. 19. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal. CAUTION: When installing guide pin bolts extreme caution should be taken not to crossthread the caliper guide pin bolts. 20. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4400 21. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 22. Set the parking brake. 23. Tighten the hub nut to a torque of 244 Nm (180 ft. lbs.). 24. Install the spring washer on the stub shaft of the outer C/V joint. 25. Install the nut retainer and cotter pin on the stub shaft of the outer C/V joint. 26. Install the wheel and tire assembly. 27. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 28. Remove jackstands or lower hoist. 29. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 30. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications DIMENSIONS: Mounting Stud Size ............................................................................................................................. .............................................................. M8 x 1.25 Boost At 20 Inches Of Manifold Vacuum ........................................................................................................................................... 3800 Nm (850 lbs.) TIGHTENING TORQUES: To Dash Panel Mounting Nuts ........................................................................................................................................................ 28 Nm (250 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4405 Vacuum Brake Booster: Description and Operation All vehicles use a 270 mm single diaphragm power brake vacuum booster. Power Brake Booster Identification The power brake booster can be identified if required, by the tag attached to the body of the booster assembly. This tag contains the following information: The production part number of the power booster assembly, the date it was built, and who was the manufacturer of the power brake vacuum booster. NOTE: The power brake booster assembly is not a repairable component and must be replaced as a complete assembly if it is found to be faulty in any way. The check valve located in the power brake booster is not repairable but it can be replaced as an assembly separate from the power brake booster. The power brake booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop vehicle. Power Brake Booster Assembly The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through the power brake booster check valve. As the brake pedal is depressed, the power brake booster's input rod moves forward. This opens and closes valves in the power booster, allowing atmospheric pressure to enter on one side of a diaphragm. Engine vacuum is always present on the other side. This difference in pressure forces the output rod of the power booster out against the primary piston of the master cylinder. As the pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4406 The different engine combinations used on this vehicle require that different vacuum hose routings to the power brake vacuum booster be used. All vacuum hoses must be routed from the engine to the power brake vacuum booster without kinks, excessively tight bends, or potential for damage to the vacuum hose. The power brake vacuum booster assembly mounts on the engine side of the dash panel, and is connected to the brake pedal by the input push rod. A vacuum line connects the power booster to the intake manifold. The master cylinder is bolted to the front of the power brake vacuum booster assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement Vacuum Brake Booster: Service and Repair Vacuum Booster Replacement Removal CAUTION: Reserve vacuum in the booster must be pumped down (removed) before removing master cylinder from vacuum booster. This is necessary to prevent the vacuum booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). 2. Remove both battery cables from battery. 3. Remove the battery thermal guard and the battery from the battery tray. 4. Remove the air inlet resonator and hoses as an assembly from the throttle body and air cleaner housing. 5. If vehicle is equipped with speed control, unplug wiring harness connector from the speed control servo. Then disconnect vacuum lines from the speed control servo and vacuum reservoir on battery tray. 6. Remove bolt attaching the speed control servo bracket to the battery tray. Slide the bracket forward to unhook it from the battery tray and remove. Battery Tray Mounting Locations 7. Remove the 2 bolts and the nut attaching the battery tray to the body of the vehicle. Electrical Connector At EGR Transducer 8. Remove the wiring harness connector from the EGR valve transducer. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 4409 Electrical And Vacuum Connections To Throttle Body 9. Remove wiring harness connectors from throttle position sensor and AIS motor on throttle body. Throttle Body Attachment To Intake Manifold 10. Remove the 2 bolts attaching the throttle body to the intake manifold and the clip attaching the wiring harness to the throttle cable bracket. Then remove the throttle body and throttle cable bracket as an assembly from the intake manifold. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 4410 Fluid Level Sensor Electrical Connection 11. Remove wiring harness connector from brake fluid level sensor in master cylinder fluid reservoir. 12. Clean the area where the master cylinder assembly attaches to the power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Attachment To Vacuum Booster 13. Remove clip, attaching drain hose for wiper module to brake tube at master cylinder. Remove drain hose from wiper module. Remove the 2 nuts, attaching the master cylinder to the vacuum booster. NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the master cylinder from the vacuum booster. 14. Remove master cylinder and brake tubes as an assembly from the vacuum booster. When master cylinder is removed, lay it out of the way on top of the left motor mount. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 4411 EGR Valve Attachment To Intake Manifold 15. Remove the EGR Valve and the vacuum transducer as an assembly from the intake manifold. 16. Disconnect vacuum hose from check valve located on vacuum booster. Do not remove check valve from power brake booster. Vacuum Booster Input Rod Retaining Pin 17. Locate the vacuum booster input rod to brake pedal connection under the instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip. 18. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. 19. Remove the 4 nuts attaching the power brake vacuum booster to the dash panel. Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly. 20. From outside the vehicle, slide power brake vacuum booster forward until its mounting studs clear dash panel. Then tilt the booster up and toward the center of vehicle to remove. CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced only as a complete assembly. Installation CAUTION: When installing the power brake vacuum booster in the vehicle be sure the heater hoses do not become trapped between the booster and the dash panel of the vehicle. 1. Position vacuum booster on dash panel using the reverse procedure of its removal. 2. Install the 4 nuts mounting the vacuum booster to the dash panel. Tighten the 4 mounting nuts to a torque of 29 Nm (250 inch lbs.). 3. Using lubriplate, or an equivalent, coat the surface of the brake pedal pin where it contacts the vacuum booster input rod. CAUTION: When installing the brake pedal pin on the power brake vacuum booster input rod, do not re-use the old retaining clip. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 4412 Retaining Pin Installed On Brake Pedal Pin 4. Install vacuum booster input rod on brake pedal pin and install a NEW retaining clip. 5. Connect the vacuum hose on the check valve in the power brake vacuum booster. 6. Install EGR Valve and vacuum transducer on the intake manifold. Install and tighten the 2 EGR valve mounting bolts to a torque of 22 Nm (200 inch lbs.). CAUTION: ^ The master cylinder is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. ^ When removing the vacuum seal from the master cylinder do not use a sharp tool. 7. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. Vacuum Seal Installed On Master Cylinder 8. Install a NEW vacuum seal on mounting flange of the master cylinder. 9. Position master cylinder on studs of vacuum booster, aligning push rod on vacuum booster with master cylinder piston. 10. Install the 2 nuts mounting the master cylinder to the vacuum booster. Tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). 11. Install the wiper module drain hose on the wiper module. Install the tie strap attaching the wiper module drain hose to brake tube at the master cylinder. Tie strap should be loosely tightened so as not to collapse the wiper module drain hose. 12. Install the wiring harness connector on the brake fluid level sensor in the master cylinder fluid reservoir. 13. Install the throttle body and throttle cable bracket on the intake manifold. Install the 2 bolts attaching the throttle body to the intake manifold and tighten to a torque of 25 Nm (225 inch lbs.) Install clip attaching the wiring harness to the throttle cable bracket. 14. Install the wiring harness connectors on the throttle position sensor and the AIS motor on throttle body. 15. Install the wiring harness connector on the EGR valve transducer. 16. Install the battery tray. Install the 2 bolts and the nut attaching the battery tray to the vehicle. Tighten the 2 bolts and the nut to a torque of 14 Nm (125 inch lbs.). 17. If vehicle is equipped with speed control, install the speed control servo and bracket on the battery tray. Install and securely tighten bolt attaching bracket to battery tray. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 4413 18. If vehicle is equipped with speed control, install the wiring harness connector on the speed control servo. Then connect the vacuum lines onto the speed control servo and vacuum reservoir on battery tray. 19. Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner housing. Securely tighten hose clamp at air cleaner housing and throttle body. 20. Install the battery and the battery thermal guard. 21. Install the battery cables on the battery. 22. Check the operation of the stop lamp switch and adjust if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 4414 Vacuum Brake Booster: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal 1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master cylinder push rod. Vacuum Seal Installed On Master Cylinder 4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When installing new vacuum seal, be sure it is squarely seated against master cylinder mounting flange and in groove of push rod. 5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6. Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to ensure proper operation of the vehicle's power brake system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES The ABS system fuse and the ABS pump/motor fuse are located in the Power Distribution Center (PDC). Refer to the sticker on the inside of the PDC cover for the location of these fuses. The PDC is located on the driver's side of the engine compartment. The fuse for the amber ABS warning lamp is located in the fuse junction block under the instrument panel. If the vehicle is equipped with traction control, the fuse for the traction control switch is located in the fuse junction block under the instrument panel. ABS RELAYS Two relays are used to control the antilock brake system. The two relays are the pump/motor relay and the system relay. The pump/motor relay and the system relay are located in the CAB. If either the pump/motor relay or the system relay is diagnosed as not functioning properly, the CAB must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications To HCU Mounting Bolts ....................................................................................................................... .................................................. 2 Nm (17 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4422 Controller Antilock Brake (CAB) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4423 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4424 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the ABS system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the CCD bus. The primary functions of the (CAB) are to: 1. monitor the antilock brake system for proper operation. 2. detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. 3. control fluid modulation to the wheel brakes while the system is in an ABS mode or the traction control system is activated. 4. store diagnostic information. 5. provide communication to the DRB scan tool while in diagnostic mode. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn on the amber ABS warning lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning lamp is turned on and the fault Diagnostic Trouble Code (DTC) is then stored in a diagnostic program memory. These DTCs will remain in the CAB memory even after the ignition has been turned off. The DTCs can be read and cleared from the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 255 key cycles of vehicle operation or 3,600 miles, whichever comes first. CONTROLLER ANTILOCK BRAKE INPUTS - wheel speed sensors (four) - stop lamp switch - ignition switch - system relay voltage - ground. - traction control lamp (if equipped) - diagnostic communication (CCD) CONTROLLER ANTILOCK BRAKE OUTPUTS - body controller communication - amber ABS warning lamp actuation - traction control lamp (if equipped) - diagnostic communication (CCD) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for replacement of the brake fluid level switch. REMOVAL Fluid Level Sensor Electrical Connection 1. Remove wiring harness connector from brake fluid reservoir level switch. Master Cylinder Brake Fluid Level Switch 2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert the brake fluid level switch into brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to the brake fluid reservoir. 2. Connect the vehicle wiring harness connector to the brake fluid level switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side > Page 4434 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 4435 Traction Control Switch: Testing and Inspection Traction Control Switch Connector 1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading between pins. Traction Control Switch Continuity Switch Position = Continuity between Actuated = Pins 1 and 2 Illumination = Pins 1 and 3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 4436 Traction Control Switch: Service and Repair Battery Negative Cable REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the over steering column bezel. 3. Remove the two screws attaching traction control switch to the bezel. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Allowable Resistance 900 - 1300 ohms Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 4441 Wheel Speed Sensor: Mechanical Specifications Front Rear Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in To Axle Or Steering Knuckle Mounting Bolt 105 in.lb 105 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Front Wheel Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 4444 Rear Wheel Speed Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4447 Wheel Speed Sensor: Diagrams Rear Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 4448 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor (FWD) One Wheel Speed Sensor (WSS) and one tone wheel are located at each front and rear wheel. Each front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is part of the outboard constant velocity joint. The rear wheel speed sensor on rear disc brake applications is mounted to the rear disc brake adapter. The rear tone wheel is an integral part of the rear wheel hub and bearing. The wheel speed sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel speed sensor. The CAB converts the AC signal into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. Correct ABS operation is dependent on accurate wheel speed signals. The vehicle's tires and wheels all must be the same size and type to generate accurate signals. Variations in tire and wheel size can produce inaccurate wheel speed signals. Improper speed sensor-to-tone wheel clearance can cause erratic speed sensor signals. The speed sensor air gap is not adjustable, but should be checked when applicable. Wheel speed sensor-to-tone wheel clearance specifications can be found in Specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 4449 Wheel Speed Sensor: Testing and Inspection Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. missing, chipped, or broken teeth - contact with the wheel speed sensor - wheel speed sensor to tone wheel alignment - wheel speed sensor to tone wheel clearance - excessive tone wheel runout - tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement on front-wheel-drive models, the tone wheel is serviceable separately. If a rear tone wheel is found to need replacement on all-wheel-drive models, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Front Speed Sensor Cable Channel Bracket 3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame rail. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector. Speed Sensor Cable To Vehicle Wiring Harness 4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect speed sensor cable from vehicle wiring harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4452 Front Wheel Speed Sensor Attaching Bolt 5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. Front Wheel Speed Sensor Cable Routing 7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front wheel speed sensor assembly from the vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut tower. CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the channel bracket. 2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4. Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link. 5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor attaching bolt to a torque of 12 Nm (105 inch lbs.) 6. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (.047 inches). 7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4453 Rear REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. CAUTION: When unplugging speed sensor cable from vehicle wiring harness, be careful not to damage pins on the electrical connectors. Also inspect connectors for any signs of previous damage. Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during removal of the speed sensor cable. Speed Sensor Cable Attachment To Brake Flex Hose 4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4454 Right Rear Speed Sensor Cable Routing 5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the axle flange, the brake tube clip and the routing clip from the track bar bracket on the axle. Rear Speed Sensor Routing Brackets And Clips 6. Remove the 2 rear wheel speed sensor cable/brake tube routing clips. Then unclip the speed sensor cable from the routing clips on rear brake tube. CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor head in an attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the sensor from side to side until free. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4455 Rear Wheel Speed Sensor Attaching Bolts 7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not come loose, do not use pliers. Tap with screw driver and hammer. 8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed sensor assembly from vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head. Note the plastic anti rotation pin must be fully seated prior to installing the attaching bolt. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. Rear Wheel Speed Sensor Attaching Bolts 2. Install the wheel speed sensor head to bearing flange attaching bolt. Tighten the attaching bolt to a torque 12 Nm (105 inch lbs.) 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inches). 4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle. The rear wheel speed sensor cable should be routed under the rear brake tube. CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during installation of the wheel speed sensor cable. 5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4456 CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the vehicle wiring harness, do not force the connectors together. If the connectors are forced together, damage to the connectors will occur. 7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into the body hole. 9. Install the tire and wheel assembly on vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4457 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement This procedure is for the removal of the ABS rear tone wheel from the rear hub and bearing on front wheel drive vehicles. Vehicles equipped with AWD have a tone wheel mounted on the driveshaft outer constant velocity joint and it is serviced with the driveshaft. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly. 3. Remove rear brake drum from the hub/bearing assembly. Rear Wheel Speed Sensor 4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing assembly. Rear Hub/Bearing Mounting Bolts 5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4458 Removing Rear Hub/Bearing From Axle 6. Remove the hub/bearing assembly from the rear axle and brake support plate. Tone Wheel Removal From Hub/Bearing Assembly 7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage by the vise jaws. Mount the hub/bearing assembly in a vise. Using Puller, Special Tool C-4693 installed as shown remove the tone wheel from the hub/bearing assembly. INSTALL Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4459 Installing Tone Wheel On Hub/Bearing Assembly 1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3. Position Driver, Special Tool 6908-1 with undercut side facing up on top of the tone wheel. Correctly Installed Tone Wheel 2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3. Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts into hub/ bearing assembly. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 7. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 8. Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inches). 9. Install the brake drum onto the rear hub/bearing assembly. 10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust the rear brakes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation OPERATION The temperature sensor, in the PCM, is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4474 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4480 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4481 Ignition Switch Lock Cylinder: Description and Operation DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION Ignition Lock Cylinder Detents The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4482 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4483 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4487 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4492 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4493 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4494 Starter Relay: Description and Operation STARTER RELAY-PCM OUTPUT Double Start Override is a feature that prevents the starter from operating if the engine is already running. This feature is accomplished with software only. There was no hardware added because of this feature. To incorporate the unique feature of Double Start Override, it was necessary to use the PCM (software) to control the starter circuit. To use the PCM it was necessary to separate the starter relay coil ground from the park neutral switch. The starter relay ground is now controlled through Pin 60 of the PCM. This allows the PCM to interrupt the ground circuit if other inputs tell it that the engine is turning. If the starter system is operating properly, it can be assumed that the override protection is also working. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4495 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED. Starter Relay Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +-5 Ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation OPERATION The temperature sensor, in the PCM, is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Voltage Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator field source (+) circuit. The voltage range is 12.9 to 15.0 volts Rated Amps Nippondenso 90 A HS PN 4727220 .................................................................................................... ..................................................................... 86 amps Nippondenso 120 A HS PN 4727325AA ............................................................................................. ................................................................... 102 amps Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 4505 Alternator: Mechanical Specifications Adjusting Strap Bolt 200 in.lb Adjusting Strap Mounting Bolt 30 ft.lb Bracket Bolt 30 ft.lb Pivot Nut 30 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4506 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4507 Alternator: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4508 Alternator: Application and ID Type = Nippondenso 90 A HS Part Number = 4727220 Type = Nippondenso 120 A HS Part Number = 4727325AA Part Number is located on the side of the generator Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4509 Alternator: Description and Operation DESCRIPTION The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. OPERATION As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode - Damaged internal fins GENERATOR FIELD-PCM OUTPUT The PCM regulates the charging system voltage within a range of 12.9 to 15.0 volts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4510 Alternator: Service and Repair REMOVAL 1. Release hood latch and open hood. Removal/Installation Of Battery Cables 2. Disconnect battery negative cable. 3. Remove windshield wiper housing, refer to Windshield Wipers and Washers for proper procedures. 4. Remove accessory drive belt. Generator Mounting Bracket 5. Remove bolt holding top of generator mount bracket to engine air intake plenum. 6. Remove bolts holding outside of generator mount bracket to generator mount plate. 7. Remove bolt holding top of generator to mount bracket. 8. Remove generator mount bracket from vehicle. 9. Rotate generator toward rear dash panel. Generator 10. Disconnect the push-in field wire connector from back of generator. 11. Remove nut holding B+ wire terminal to back of generator. 12. Separate B+ terminal from generator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4511 Generator Pivot Bolt 13. Remove bolt holding bottom of generator to lower pivot bracket. Generator 14. Remove generator from vehicle. INSTALLATION 1. Place generator in position on vehicle. 2. Install bolt to hold bottom of generator to lower pivot bracket. 3. Place B+ terminal in position on generator. 4. Install nut to hold B+ wire terminal to back of generator. 5. Connect the push-in field wire connector into back of generator. 6. Rotate generator forward away from dash panel. 7. Place generator mount bracket in position on vehicle. 8. Install bolt to hold top of generator to mount bracket. 9. Install bolts to hold outside of generator mount bracket to generator mount plate. 10. Install bolt to hold top of generator mount bracket to engine air intake plenum. 11. Install accessory drive belt. 12. Install windshield wiper housing, refer to Windshield Wipers and Washers for proper procedures. 13. Connect battery negative cable. 14. Verify generator charge rate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation DESCRIPTION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. OPERATION The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly Also refer to Charging System Operation for additional information. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair Ignition Lock: Service and Repair This article has been updated by technical service bulletin number 19-06-99 Dated Sep. 17, 1999. Note: This bulletin applies to vehicles equipped with an automatic transaxle. Ignition Switch Housing Service The ignition switch housing, p/n 04690523, is now available as a separate service part. This part eliminates the need to replace the complete steering column assembly if the service issue only relates to the ignition switch housing. The service procedure to replace the ignition switch housing is below. REMOVAL 1. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. 2. Remove the screws attaching the lower steering column cover to the instrument panel, then remove the cover from the lower instrument panel. 3. Remove the parking brake release cable from the parking brake release lever, then move the lower steering column cover out of the way. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 4519 4. Remove the 10 bolts attaching the lower steering column cover liner to the instrument panel, then remove the lower steering column cover liner. 5. Remove the 3 screws attaching the upper and lower shrouds to the steering column, then separate and remove both shrouds. 6. Remove the trim bezel on the instrument panel above the steering column. The trim bezel is mounted to the instrument panel using 2 screws (one on each side of the column) and retaining clips. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 4520 7. Remove the 2 screws securing the steering column fixed shroud to the steering column, then remove the shroud. 8. Remove the two screws holding the metal cover in place below the shifter/ignition interlock linkage, then remove the cover. 9. Disconnect the shifter/ignition interlock link from the lever on the lock cylinder housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 4521 10. Remove the key cylinder. To do this: - Turn the key placing the key cylinder in the ON position. - Depress and hold the retaining tab on the bottom of the lock cylinder housing. - Pull the key cylinder straight out of the lock cylinder housing. 11. Remove the vehicle wiring harness connector from the key cylinder halo lamp. 12. Remove the key cylinder halo lamp from the lock cylinder housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 4522 13. Remove the ignition switch mounting screw. 14. Depress the two retaining tabs, then remove the ignition switch from the lock cylinder housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 4523 15. Disconnect both tilt mechanism springs from their mounting posts on the tilt housing, then move them to the side out of the way. 16. While supporting the lock cylinder housing, remove both mounting screws securing the lock cylinder housing to the column. 17. Remove the lock cylinder housing from the bottom of the steering column. INSTALLATION 1. Install the lock cylinder housing in the bottom of the steering column lining up the mounting holes. 2. Install the self-tapping lock cylinder housing mounting screws through the top of the column into the housing. Tighten the two mounting screws to a torque of 11 Nm (100 inch lbs.). 3. Connect both tilt mechanism springs back onto their mounting posts making sure the spring hooks engage the grooves in the posts. 4. Ensure that the ignition switch and the actuator shaft in the lock cylinder housing are in the ON position. 5. Carefully install the ignition switch over the actuator shaft. The switch will snap over the retaining tabs on the housing. 6. Install the ignition switch mounting screw. 7. Install the key cylinder halo lamp on the lock cylinder housing. 8. Install the vehicle wiring harness connector onto the key cylinder halo lamp. 9. Install the key cylinder (with key in it turned to the ON position) by sliding it straight into the lock cylinder housing aligning the retaining tab on the key cylinder with the hole in the lock cylinder housing. 10. Turn the key to the OFF position and remove the key. 11. Connect the shifter/ignition interlock link to the lever on the lock cylinder housing by aligning the retaining tab on the lever with the ramp on the link, then pushing the two together. 12. Install the metal cover in place below the shifter/ignition interlock linkage using the two screws. CAUTION: After the completion of step 12 in the installation process, you must verify that the shift lever interlock functions properly. With ignition Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 4524 key removed from lock cylinder and brake pedal depressed, attempt to shift out of park. If the lever moves out of the park position you must repeat steps 11 and 12 of the installation procedure. 13. Install the steering column fixed shroud on the steering column using its 2 mounting screws. 14. Install the trim bezel on the instrument panel above the steering column. The trim bezel is mounted to the instrument panel using 2 screws (one on each side of the column) and retaining clips. 15. Install the lower steering column shroud on the steering column. Install and securely tighten the center screw attaching the lower shroud to the tilt head on the column. 16. Install the upper steering column shroud over the tilt head of the steering column snapping it into place on the lower shroud. Install and securely tighten the 2 remaining screws attaching the upper shroud to the lower shroud. 17. Install the steering column cover liner on the instrument panel below the steering column. Install and securely tighten the 10 bolts attaching the steering column cover liner to the instrument panel. 18. Install the parking brake pedal release cable on the parking brake release lever in the lower steering column cover. 19. Install the lower steering column trim cover on the instrument panel below the steering column. Install and securely the screws attaching the lower steering column cover to the instrument panel. 20. Connect the negative (ground) cable on the battery terminal. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4534 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4540 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4541 Ignition Switch Lock Cylinder: Description and Operation DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION Ignition Lock Cylinder Detents The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4542 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4543 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Transmission Range Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4547 Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Power rating = 1.2 K.w. Voltage = 12 Volts Free Running Test Voltage = 11 Amperage Draw = 73 amp Minimum Speed = 3401 rpm Solenoid Closing Voltage = 7.5 Volts Cranking Amperage Draw Test = 150 - 200 amps Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 4552 Starter Motor: Mechanical Specifications Starter Mounting Bolt 50 ft.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4553 Starter Motor: Application and ID Manufacturer = Nippondenso Brushes = 4 Fields = 4 Poles = 4 Drive = Conventional Gear Train Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage draw. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4554 Starter Motor: Service and Repair REMOVAL 1. Release hood latch and open hood. Battery Negative Cable 2. Disconnect and isolate the battery negative cable. 3. Hoist and support vehicle on safety stands. Starter - Engine Wire Connectors 4. Remove nut holding B+ terminal to starter solenoid. 5. Disconnect solenoid connector from starter. Starter Bolts Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4555 6. Remove bolts holding starter to transaxle bell-housing. Starter 7. Remove starter from bell-housing. 8. Separate starter spacer from transaxle bell-housing. INSTALLATION 1. Place starter spacer in position on transaxle bell-housing, flange toward flywheel. 2. Place starter in position on bellhousing. 3. Install bolts to hold starter to transaxle bell-housing. 4. Connect solenoid connector into starter. 5. Install nut to hold B+ terminal to starter solenoid. 6. Lower vehicle. 7. Connect battery negative cable. 8. Verify starter operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4559 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4560 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4561 Starter Relay: Description and Operation STARTER RELAY-PCM OUTPUT Double Start Override is a feature that prevents the starter from operating if the engine is already running. This feature is accomplished with software only. There was no hardware added because of this feature. To incorporate the unique feature of Double Start Override, it was necessary to use the PCM (software) to control the starter circuit. To use the PCM it was necessary to separate the starter relay coil ground from the park neutral switch. The starter relay ground is now controlled through Pin 60 of the PCM. This allows the PCM to interrupt the ground circuit if other inputs tell it that the engine is turning. If the starter system is operating properly, it can be assumed that the override protection is also working. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4562 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED. Starter Relay Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +-5 Ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection Starter Solenoid: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED. 1. Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. Refer to Battery Tests. 2. Perform Starter Solenoid test BEFORE performing the starter relay test. 3. Raise the vehicle. 4. Perform a visual inspection of the starter/starter solenoid for corrosion, loose connections or faulty wiring. 5. Lower the vehicle. 6. Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. 7. Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector. a. If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. b. If engine does not or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose or corroded connections. Particularly at starter terminals. c. Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 4570 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Auxiliary Power Outlet: Connector Views Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Power Distribution Center -- Sheet 8w-10-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Diagrams Diode: Diagrams Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Diagrams > Page 4596 Diodes Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations Power Distribution Center: Component Locations Power Distribution Center & Powertrain Control Module (PCM) Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4601 Power Distribution Center: Connector Locations Connector Pin Identification (Part 1 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4602 Connector Pin Identification (Part 2 Of 15) Connector Pin Identification (Part 3 Of 15) Connector Pin Identification (Part 4 Of 15) Connector Pin Identification (Part 5 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4603 Connector Pin Identification (Part 6 Of 15) Connector Pin Identification (Part 7 Of 15) Connector Pin Identification (Part 8 Of 15) Connector Pin Identification (Part 9 Of 15) Connector Pin Identification (Part 10 Of 15) Connector Pin Identification (Part 11 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4604 Connector Pin Identification (Part 12 Of 15) Connector Pin Identification (Part 13 Of 15) Connector Pin Identification (Part 14 Of 15) Connector Pin Identification (Part 15 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4605 Power Distribution Center: Diagrams Power Distribution Center C1 Power Distribution Center C2 Power Distribution Center C3 Power Distribution Center C4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4606 Power Distribution Center C5 Power Distribution Center C6 Power Distribution Center C7 Power Distribution Center C8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations For fuse location and identification, refer to Electrical Accessory Panel (Power Distribution Center) and/or Fuse Block (Junction Block) Locations, Components. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4610 Fuse: Diagrams Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4611 Junction Block Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4612 Power Distribution Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4613 Power Distribution Center Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Fuse Block: Connector Views Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Junction Block C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Junction Block C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Junction Block C3 (D) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Junction Block C4 (C) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Fuse Block: Electrical Diagrams Except Chrysler Junction Block -- Sheet 8w-12-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Junction Block -- Sheet 8w-12-9 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Junction Block -- Sheet 8w-12-10 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 Junction Block -- Sheet 8w-12-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 Junction Block -- Sheet 8w-12-12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 Junction Block -- Sheet 8w-12-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Junction Block -- Sheet 8w-12-14 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 Junction Block -- Sheet 8w-12-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 Junction Block -- Sheet 8w-12-16 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Junction Block -- Sheet 8w-12-17 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Junction Block -- Sheet 8w-12-18 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Junction Block -- Sheet 8w-12-19 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 Junction Block -- Sheet 8w-12-20 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Junction Block -- Sheet 8w-12-21 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Junction Block -- Sheet 8w-12-22 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Junction Block -- Sheet 8w-12-23 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Junction Block -- Sheet 8w-12-24 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions Multiple Junction Connector: Technical Service Bulletins Electrical - Wiring Schematics Revisions NUMBER: 26-12-99G GROUP: Miscellaneous DATE: December, 1999 THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the wiring schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4664 8W-44-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4665 8W-44-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4666 8W-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4667 8W-50-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4668 8W-50-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4669 8W-50-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4670 8W-80-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4671 8W-90-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4672 8W-90-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions Wiring Harness: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4677 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4678 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 4683 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Auxiliary Power Outlet: Connector Views Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Power Distribution Center -- Sheet 8w-10-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Diagrams Diode: Diagrams Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Diagrams > Page 4709 Diodes Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations Power Distribution Center: Component Locations Power Distribution Center & Powertrain Control Module (PCM) Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4714 Power Distribution Center: Connector Locations Connector Pin Identification (Part 1 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4715 Connector Pin Identification (Part 2 Of 15) Connector Pin Identification (Part 3 Of 15) Connector Pin Identification (Part 4 Of 15) Connector Pin Identification (Part 5 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4716 Connector Pin Identification (Part 6 Of 15) Connector Pin Identification (Part 7 Of 15) Connector Pin Identification (Part 8 Of 15) Connector Pin Identification (Part 9 Of 15) Connector Pin Identification (Part 10 Of 15) Connector Pin Identification (Part 11 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4717 Connector Pin Identification (Part 12 Of 15) Connector Pin Identification (Part 13 Of 15) Connector Pin Identification (Part 14 Of 15) Connector Pin Identification (Part 15 Of 15) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4718 Power Distribution Center: Diagrams Power Distribution Center C1 Power Distribution Center C2 Power Distribution Center C3 Power Distribution Center C4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4719 Power Distribution Center C5 Power Distribution Center C6 Power Distribution Center C7 Power Distribution Center C8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations For fuse location and identification, refer to Electrical Accessory Panel (Power Distribution Center) and/or Fuse Block (Junction Block) Locations, Components. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4723 Fuse: Diagrams Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4724 Junction Block Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4725 Power Distribution Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4726 Power Distribution Center Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuses Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 Fuse Block: Connector Views Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 Junction Block C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 Junction Block C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 Junction Block C3 (D) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Junction Block C4 (C) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Fuse Block: Electrical Diagrams Except Chrysler Junction Block -- Sheet 8w-12-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 Junction Block -- Sheet 8w-12-9 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Junction Block -- Sheet 8w-12-10 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Junction Block -- Sheet 8w-12-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Junction Block -- Sheet 8w-12-12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Junction Block -- Sheet 8w-12-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Junction Block -- Sheet 8w-12-14 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Junction Block -- Sheet 8w-12-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Junction Block -- Sheet 8w-12-16 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Junction Block -- Sheet 8w-12-17 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Junction Block -- Sheet 8w-12-18 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Junction Block -- Sheet 8w-12-19 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Junction Block -- Sheet 8w-12-20 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Junction Block -- Sheet 8w-12-21 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 Junction Block -- Sheet 8w-12-22 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Junction Block -- Sheet 8w-12-23 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Junction Block -- Sheet 8w-12-24 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions Multiple Junction Connector: Technical Service Bulletins Electrical - Wiring Schematics Revisions NUMBER: 26-12-99G GROUP: Miscellaneous DATE: December, 1999 THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the wiring schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4777 8W-44-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4778 8W-44-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4779 8W-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4780 8W-50-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4781 8W-50-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4782 8W-50-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4783 8W-80-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4784 8W-90-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4785 8W-90-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions Wiring Harness: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4790 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4791 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine NOTES: - All specifications are given in degrees. - All wheel alignments are to be set at curb height. FRONT: Camber (All Vehicles Except Those With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17): Preferred Setting ................................................................................................................................. ..................................................................... +0.15° Acceptable Range .............................................. ........................................................................................................................................ -0.25 to +0.55° Camber (Vehicles With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17): Preferred Setting .. .............................................................................................................................................................. ...................................... +0.05° Acceptable Range ............................................................................. ......................................................................................................... -0.25 to +0.55° Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ............................................... ......................................................................................................................................................... +0.0° Acceptable Range ...................................................................................................................... ................................................................................ 0.50° Caster [1]: Preferred Setting ................................................................................................................ ...................................................................................... +1.40° Acceptable Range ............................. ....................................................................................................................................................... +0.40° to +2.40° Cross Caster (Maximum Side-to-Side Difference): Preferred Setting ................................................. ......................................................................................................................................................... 0.0° Acceptable Range ........................................................................................................................ .............................................................................. 1.00° Total Toe [2]: Preferred Setting ........................................................................................................... ........................................................................................... +0.10° Acceptable Range ........................ ............................................................................................................................................................. -0.10° to +0.30° Total Toe (Maximum Side-to-Side Difference): Preferred Setting ....................................................... ................................................................................................................................................... 0.0° Acceptable Range ............................................................................................................................... ....................................................................... 0.06° Curb Height: Standard ......................................................................................................................................................... 783.5 mm ±10 mm (30.85 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) REAR: Camber [1]: Preferred Setting .............................................................................................................. ......................................................................................... -0.10° Acceptable Range .......................... ............................................................................................................................................................ -0.35 to +0.15° Total Toe [1, 2]: Preferred Setting ....................................................................................................... ................................................................................................... 0.0° Acceptable Range .................... .............................................................................................................................................................. ... -0.40° to +0.40° Thrust Angle [1]: Preferred Setting ...................................................................................................... .................................................................................................... 0.0° Acceptable Range ................... .............................................................................................................................................................. .... -0.30° to +0.30° Curb Height: Standard ......................................................................................................................................................... 802.5 mm ±10 mm (31.59 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) [1] For reference only. These are non-adjustable angles. [2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 4797 Alignment: Specifications All Except W/Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17 NOTES: - All specifications are given in degrees. - All wheel alignments are to be set at curb height. FRONT: Camber: Preferred Setting ................................................................................................................... ................................................................................... +0.15° Acceptable Range ................................ ...................................................................................................................................................... -0.25 to +0.55° Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ............................................... ......................................................................................................................................................... +0.0° Acceptable Range ...................................................................................................................... ................................................................................ 0.50° Caster [1]: Preferred Setting ................................................................................................................ ...................................................................................... +1.40° Acceptable Range ............................. ....................................................................................................................................................... +0.40° to +2.40° Cross Caster (Maximum Side-to-Side Difference): Preferred Setting ................................................. ......................................................................................................................................................... 0.0° Acceptable Range ........................................................................................................................ .............................................................................. 1.00° Total Toe [2]: Preferred Setting ........................................................................................................... ........................................................................................... +0.10° Acceptable Range ........................ ............................................................................................................................................................. -0.10° to +0.30° Total Toe (Maximum Side-to-Side Difference): Preferred Setting ....................................................... ................................................................................................................................................... 0.0° Acceptable Range ............................................................................................................................... ....................................................................... 0.06° Curb Height: Standard ......................................................................................................................................................... 747.5 mm ±10 mm (29.43 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) REAR: Camber [1]: Preferred Setting .............................................................................................................. ............................................................................................ 0.0° Acceptable Range ........................... ........................................................................................................................................................... -0.25 to +0.25° Total Toe [1, 2]: Preferred Setting ....................................................................................................... ................................................................................................... 0.0° Acceptable Range .................... .............................................................................................................................................................. ... -0.40° to +0.40° Thrust Angle [1]: Preferred Setting ...................................................................................................... .................................................................................................... 0.0° Acceptable Range ................... .............................................................................................................................................................. .... -0.30° to +0.30° Curb Height: Standard ......................................................................................................................................................... 766.0 mm ±10 mm (30.15 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) [1] For reference only. These are non-adjustable angles. [2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 4798 Alignment: Specifications With Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17 NOTES: - All specifications are given in degrees. - All wheel alignments are to be set at curb height. FRONT: Camber: Preferred Setting ................................................................................................................... ................................................................................... +0.05° Acceptable Range ................................ ...................................................................................................................................................... -0.35 to +0.45° Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ............................................... ......................................................................................................................................................... +0.0° Acceptable Range ...................................................................................................................... ................................................................................ 0.50° Caster [1]: Preferred Setting ................................................................................................................ ...................................................................................... +1.40° Acceptable Range ............................. ....................................................................................................................................................... +0.40° to +2.40° Cross Caster (Maximum Side-to-Side Difference): Preferred Setting ................................................. ......................................................................................................................................................... 0.0° Acceptable Range ........................................................................................................................ .............................................................................. 1.00° Total Toe [2]: Preferred Setting ........................................................................................................... ........................................................................................... +0.10° Acceptable Range ........................ ............................................................................................................................................................. -0.10° to +0.30° Total Toe (Maximum Side-to-Side Difference): Preferred Setting ....................................................... ................................................................................................................................................... 0.0° Acceptable Range ............................................................................................................................... ....................................................................... 0.06° Curb Height: Standard ......................................................................................................................................................... 753.5 mm ±10 mm (29.66 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) REAR: Camber [1]: Preferred Setting .............................................................................................................. ............................................................................................ 0.0° Acceptable Range ........................... ........................................................................................................................................................... -0.25 to +0.25° Total Toe [1, 2]: Preferred Setting ....................................................................................................... ................................................................................................... 0.0° Acceptable Range .................... .............................................................................................................................................................. ... -0.40° to +0.40° Thrust Angle [1]: Preferred Setting ...................................................................................................... .................................................................................................... 0.0° Acceptable Range ................... .............................................................................................................................................................. .... -0.30° to +0.30° Curb Height: Standard ......................................................................................................................................................... 772.0 mm ±10 mm (30.39 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed ............................................................................................................................ 12.5 mm (0.5 inch) [1] For reference only. These are non-adjustable angles. [2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4799 Alignment: Description and Operation Vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension angles. These angles are what effects the handling and steering of the vehicle when it is in motion. The method of checking a vehicle's front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the equipment being used should always be followed to ensure accuracy of the alignment, except when alignment specifications recommended by Chrysler Corporation differ. Typical wheel alignment angles and measurements are camber, caster, toe, and thrust angle. Alignment Camber And Toe - Camber is the number of degrees the top of the tire and wheel are tilted either inward or outward. Camber is a tire wearing angle. Excessive negative camber will cause tread wear at the inside of the tire, while excessive positive camber will cause outside tire wear. - Caster is the number of degrees of forward or rearward tilt of the steering knuckle. Forward tilt provides a negative caster angle, while rearward tilt provides a positive caster angle. Caster is not adjustable on this vehicle. - Cross camber is the difference between left and right camber. The right side camber is to be subtracted from the left, resulting in the cross camber reading. For example, if the left camber is +0.3° and the right camber is 0.0°, the cross camber would be +0.3°. - Toe is measured in degrees or inches and is the difference in width between the centered leading and trailing edges of the tires on the same axle. Toe-in means that the front width is more narrow than the rear. Toe-out means that the front width is wider than the rear. - Thrust angle is defined as the average of the toe settings on each rear wheel. If this measurement is out of specification, readjust the rear wheel toe so that each wheel has 1/2 of the total toe measurement. When readjusting, do not exceed the total toe specification. Wheel alignment on this vehicle is to be checked and all alignment adjustments made with the vehicle at its curb height specification. Curb height is the riding height of the vehicle measured from a certain point on the vehicle to the ground while the vehicle is setting on a flat, level surface. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4800 Alignment: Testing and Inspection PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. If curb height is out of specifications, check for broken or sagged springs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb Height Measurement Alignment: Service and Repair Curb Height Measurement The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, the maximum left-to-right differential is not to exceed 12.5 mm (0.5 inch). 3. Compare the measurements to the specifications. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 4803 Alignment: Service and Repair Wheel Alignment 1. Position the vehicle on an alignment rack. 2. Perform the PRE-WHEEL ALIGNMENT INSPECTION. 3. Install all required alignment equipment on the vehicle per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 4. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. 5. If front camber and caster are not within specifications, proceed to CAMBER AND CASTER below. If caster and camber are within specifications, proceed to TOE which can be found following CAMBER AND CASTER. Rear camber, caster and toe are not adjustable. If found not to be within specifications, reinspect for damaged suspension or body components and replace as necessary. CAMBER AND CASTER Camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as NET BUILD. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles. Camber and caster should be checked to ensure they meet vehicle specifications. If front camber is found not to meet alignment specifications, it can be adjusted using an available camber adjustment bolt package. Before installing a camber adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension components for any signs of damage or bending. CAUTION: Do not attempt to adjust the vehicles wheel; alignment by heating, bending or by performing any other modification to the vehicle's front suspension components or body. If camber readings are not within specifications, use the following procedure to install the front camber adjustment bolt package and then adjust front camber. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains 2 flange bolts, 2 cam bolts, 2 dog bone washers, and 4 nuts. This package services both sides of the vehicle. Use the package to attach the strut clevis bracket to the steering knuckle after the strut clevis bracket has been modified. To install and adjust the camber adjustment bolt package, follow the procedure below. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. 2. Remove the front tire and wheel assemblies. CAUTION: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to support the steering knuckle assembly or if required remove the brake flex hose from the caliper assembly. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. Clevis Bracket To Steering Knuckle Attaching Bolts 3. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard. Separate the steering knuckle from the strut clevis bracket and position steering knuckle so it is out of the way of the strut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 4804 Strut Clevis Bracket Bolt Hole Grinding Area CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the hole beyond the indentations on the sides of the strut clevis bracket. 4. Using an appropriate grinder and grinding wheel, slot the bottom hole in both sides of the strut clevis bracket. CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog bone washers from the service package must be used to attach the steering knuckle to the strut after the mounting hole is slotted. Package Bolts Correctly Installed (left Shown) 5. Position the knuckle back into the strut clevis bracket. Install a flanged bolt from the service package into the upper mounting hole. Install a cam bolt into the bottom mounting hole. Both bolts should point forward once installed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 4805 Dog Bone Washer And Nuts Installed On Attaching Bolts 6. Install a dog bone washer on the steering knuckle to strut clevis bracket attaching bolts, then install the nuts onto the bolts from the service package. Tighten the bolts just enough to hold the steering knuckle in position when adjusting camber, while still allowing the steering knuckle to move in clevis bracket. 7. Repeat the procedure to the other side strut clevis bracket. 8. Reinstall both front tire and wheel assemblies and tighten to specifications. 9. Lower the vehicle. Jounce the front and rear of vehicle an equal amount of times. Camber Adjustment Cam Bolt 10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket. When camber is set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce front and rear of vehicle an equal amount of times and verify front camber setting. Torque both front strut to steering knuckle attaching bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4 turn after the required torque is met. 11. If toe readings obtained are not within the required specification range, adjust toe to meet the preferred specification setting. Toe is adjustable using the following procedure. TOE 1. Center the steering wheel and lock in place using a steering wheel clamp. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb Height Measurement > Page 4806 Front Wheel Toe Adjustment 2. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front toe to the preferred toe specification. 3. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 4. Adjust steering gear to tie rod boots at the inner tie rod. 5. Remove steering wheel clamp. 6. Remove the alignment equipment. 7. Road test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint Stud Nut/Bolt ........................................................................................................................ ............................................... 145 Nm (105 ft. lbs.) Wheel Stop ........................................................ ....................................................................................................................................... 95 Nm (70 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4811 Front Steering Knuckle: Description and Operation Front Steering Knuckle The steering knuckle is a single casting with legs machined for attachment of the strut damper, steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has the front hub and bearing mounted to it. The hub and bearing is positioned through the knuckle, with the drive shaft constant velocity stub shaft splined through the center of the hub. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4812 Front Steering Knuckle: Testing and Inspection The front suspension knuckle is not a repairable component of the front suspension. It must be replaced. If bent, broken, or damaged in any way, do not attempt to straighten or repair the steering knuckle. Service replacement of the front hub/bearing assembly can be done with the front steering knuckle remaining on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal REMOVAL 1. Raise vehicle on jack stands or centered on a frame contact type hoist. Hub And Bearing To Stub Axle Retaining Nut 2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire assembly from the vehicle. Wave Washer 4. Remove the wave washer from the end of the end of the stub axle. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4815 Front Disc Brake Caliper Attaching Bolts 6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts. Brake Caliper Mounting To Steering Knuckle 7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle. Correctly Supported Disc Brake Caliper 8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly. Do not allow the brake caliper assembly to hang by the brake flex hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4816 Remove/Install Brake Rotor 9. Remove the brake rotor from the hub and bearing assembly. Removing Tie Rod End Attaching Nut 10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench. Tie Rod End Removal From Steering Knuckle Arm 11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4817 Front Wheel Speed Sensor 12. Remove the front wheel speed sensor from the steering knuckle. Wheel Stop Location On Steering Knuckle 13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt when assembling the steering knuckle to the ball joint , the pinch bolt must be installed from the rear facing the front on the vehicle. Control Arm To Steering Knuckle Attachment 14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4818 Separating Ball Joint Stud From Steering Knuckle 15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported. Steering Knuckle Separation From Driveshaft 16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4819 Fig. 21 Strut To Steering Knuckle Mounting Bolt Removal 17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the steering knuckle from the strut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4820 Front Steering Knuckle: Service and Repair Installation INSTALLATION 1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to Hub And Bearing Assembly Service. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. Correctly Installed Eccentric Attaching Bolt CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket. 2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn. 3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly. 4. Install a new steering knuckle to ball joint stud, clamping bolt and nut. Tighten the clamping bolt and nut to a torque of 145 Nm (105 ft. lbs.). Torquing Tie Rod End Attaching Nut 5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.). 6. Install braking disc on hub and bearing assembly. 7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment. 8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake caliper assembly attaching bolts to a torque of 22 Nm (195 inch. lbs.). 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut. 10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor attaching bolt to a torque of 7 Nm (60 inch. lbs.). 11. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4821 12. Lower vehicle. Torquing Front Stub Axle To Hub Nut 13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 203 Nm (150 ft. lbs.) 14. Install the spring wave washer on the end of the stub axle. 15. Install the hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 16. Set front Toe on vehicle to required specification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4827 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4828 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4829 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid 1.7 pt (US) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 4832 Power Steering Fluid: Fluid Type Specifications All models Mopar Power Steering Fluid or equivalent Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4833 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4834 Power Steering Fluid: Service and Repair WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. CAUTION: Do not use automatic transmission fluid in the power steering system. Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. The dipstick should indicate COLD when the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). Do not overfill the power steering system. Use only Mopar Power Steering Fluid, or an equivalent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Description and Operation Power Steering Fluid Reservoir: Description and Operation All vehicles use a remote mounted reservoir for the power steering fluid. The power steering fluid remote reservoir is mounted to the right fender shield under the hood. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Description and Operation > Page 4838 Power Steering Fluid Reservoir: Service and Repair REMOVE Remote Power Steering Fluid Reservoir 1. Remove the filler cap from remote power steering fluid reservoir. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove at power steering pump, the power steering fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain out of the reservoir and hose. 4. Lower vehicle. 5. Remove the fluid supply hose from the remote power steering fluid reservoir. 6. Remove the 2 mounting screws attaching the remote fluid reservoir to the inner fender. 7. Remove remote reservoir from inner fender. INSTALL 1. Install remote power steering fluid reservoir on inner fender, by first inserting tab on reservoir into hole in inner fender. Then rotate reservoir so mounting tabs are against inner fender. 2. Install and securely tighten the 2 reservoir mounting screws. Power Steering Fluid Hose Routing Clip CAUTION: The power steering fluid reservoir to power steering pump supply hose must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube. This will prevent the hose from coming in contact with the accessory drive belt. The power steering fluid supply hose must be located in its correct position by clipping it to the stud in the strut tower. 3. Install the fluid supply hose onto the power steering fluid reservoir fitting. Install the hose clamp on the fluid supply hose at the fluid reservoir. Be sure hose clamp is installed past bead on fluid reservoir fitting. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose at the power steering pump. Be sure hose clamp is installed past bead on pump fitting. 6. Lower vehicle. 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper level and let the fluid settle for at least two 2 minutes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Description and Operation > Page 4839 9. Start the engine and let run for a few seconds. Then turn the engine off. 10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4848 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4849 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4850 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4851 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4852 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4853 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4859 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4860 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4861 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4862 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4863 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4864 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 4865 Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ................................................ 31 Nm (275 inch lbs.) Routing Bracket To Suspension Cradle .................................................................................................................................................... 28 Nm (21 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 4866 Power Steering Line/Hose: Description and Operation Power Steering Hoses The power steering fluid hoses connect the components of the power steering system. They transfer fluid from one component to the next. The power steering fluid supply hose is a formed hose that connects the power steering fluid reservoir to the power steering pump. It is secured at both ends using standard adjustable clamps. The power steering fluid pressure hose is a high pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting with an O-ring is used at both ends to connect the components. The power steering fluid return hose is a formed metal and rubber hose that connects the gear back to the power steering pump. A standard tube nut fitting with an O-ring is used to connect it to the gear. It is secured to the power steering pump using a standard adjustable clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump REMOVE Fluid Supply Hose At Power Steering Fluid Reservoir 1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. Power Steering Fluid Hose Routing Clip 3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the power steering fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain out of the reservoir and hose. 6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle. Hose is removed from the top of the engine compartment. INSTALL CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube. This routing will prevent the power steering fluid supply hose from coming in contact with the accessory drive belt. 1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on fluid reservoir fitting. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on pump fitting. 5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is installed in a position to correctly align with stud in strut tower. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4869 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper level and let the fluid settle for at least two minutes. 9. Start the engine and let run for a few seconds. Then turn the engine off. 10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4870 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. For part reference and part location for the vehicle that is being serviced, refer to the illustrations. These show the hose bracket locations, hose routings and fitting locations by the engine application of the vehicle. Use these images when referring to the removal or installation procedures for the power steering hoses listed below. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel tube connection. Remove the hose clamp from the power steering fluid return hose. Remove power steering fluid return hose from steel tube and allow power steering fluid to drain from pump. Pressure Hose Connection To Power Steering Pump 5. Remove the power steering fluid pressure line from the power steering pump pressure fitting. Drain excess power steering fluid from hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4871 6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle. 7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid pressure hose. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power steering pressure hose to the fittings on the power steering pump and steering gear. Route hose avoiding tight bends or kinking. Do not bend tube ends of the power steering hoses when installing. 4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces of the vehicle. CAUTION: When tightening and torquing the pressure hose at the power steering pump, the pressure hose is to be rotated against the fluid return hose fitting on the pump. 5. Tighten all fasteners shown for specific applications to their correct torques listed below: - Pump End Tube Nut 34 Nm (25 ft. lbs.) - Gear End Tube Nut 34 Nm (25 ft. lbs.) - Pump Bracket Nut 40 Nm (30 ft. lbs.) 6. Install the power steering fluid return hose on the steel tube at the front suspension cradle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4872 7. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch. lbs.). CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. 8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 9. After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4873 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. For part reference and part location for the vehicle that is being serviced, refer to the images. These show the hose bracket locations, hose routings and fitting locations by the engine application of the vehicle. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube connection. Remove hose clamp where rubber portion of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber hose from steel tube and allow power steering fluid to drain from pump. 5. Remove the power steering fluid return hose from the power steering pump return hose fitting. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route hose smoothly avoiding tight bends or kinking. Hose must remain away from the exhaust system and not come in contact with any unfriendly surfaces of the vehicle. 3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch. lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is to prevent overheating of the power steering fluid hoses. 5. When used, position the protective heat sleeves on the power steering hoses so they cover the connection to the power steering pump. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 6. After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4878 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4879 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4880 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Flow Control Valve Fitting .................................................................................................................... ................................................... 75 Nm (55 ft. lbs.) Mounting Bolts ................................................... ...................................................................................................................................... 54 Nm (40 ft. lbs.) Rear Bracket To Engine Mounting Bolts .................................................................................................................................................. 54 Nm (40 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 4883 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow at 1500 RPM & Min. Pressure ............................................................................................................................ 5.0 - 7.0 Liters/Min (1.3 - 1.9 GPM) Control Valve Pressure Relief ....................................................................................................................................... 9653 - 10342 kPa (1400 - 1500 psi) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4884 Power Steering Pump: Service Precautions WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings or power steering gear ports to prevent entry of foreign material into the components. NOTE: Do not use any type of automatic transmission fluid in the power steering system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4885 Power Steering Pump: Description and Operation Hydraulic pressure for the operation of the power steering gear is provided by a belt driven power steering pump. The power steering pump is a constant flow rate and displacement vane type pump. The power steering pump used on all applications is the Vane-Submerged remote reservoir style power steering pump. The remote reservoir type pump has the pump housing and internal components combined with the fluid housing. But it has a remote reservoir for the power steering fluid supply. The power steering pump is mounted on the back side of the engine and is accessed from underneath the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation Power Steering Pump: Service and Repair Power Steering Pump Initial Operation CAUTION: The fluid level should be checked with engine off to prevent injury from moving components. Use only Mopar(R) Power Steering Fluid. Do not use automatic transmission fluid. Do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two 2 minutes. 2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4888 Power Steering Pump: Service and Repair Power Steering Pump Overhaul The only serviceable part of the power steering pump is the pulley. The procedure following is for removal and installation of the pulley from the pump once the pump is removed from the vehicle. DISASSEMBLY 1. Remove the power steering pump from the vehicle. 2. Remove the pulley from the shaft of the power steering pump using Puller C-4333 or C-4068. CAUTION: Do not hammer on power steering pump pulley. This will damage the pulley and the power steering pump. 3. Replace pulley if it is found to be bent, cracked, or loose. ASSEMBLY 1. Install the pulley with Installer C-4063. Do not use the tool adapters. 2. Ensure that the tool and the pulley remain aligned with the pump shaft. Prevent the pulley from being cocked on the shaft. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4889 Pulley To Pump Shaft Location 3. Install the pulley until it is flush with the end of the power steering pump shaft. 4. Install the power steering pump on the vehicle. NOTE: Once the pump is installed on the vehicle, run the engine until warm (5 min.) and note any belt chirp. If chirp exists, move the pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press the pulley on 1.0 mm (0.040 inch). Be careful that the pulley does not contact the pump mounting bolts. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4890 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation Installation INSTALLATION 1. Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel of the vehicle. 2. Install the power steering pump on its mounting bracket. Install the 3 power steering pump mounting bolts. Tighten the power steering pump mounting bolts to a torque of 54 Nm (40 ft. lbs.). 3. Install the support bracket attaching rear of power steering pump to engine. Tighten the nut and bolt holding the strut assembly to bracket and the intake manifold stud to a torque of 54 Nm (40 ft. lbs). NOTE: Before installing power steering pressure hose on power steering pump, inspect the O-ring on the power steering pressure hose for damage and replace if required. 4. Install the power steering fluid pressure line onto the output fitting of the power steering pump. Tighten the pressure line to pump fitting tube nut to a torque of 31 Nm (275 inch. lbs.). 5. Install the power steering fluid, low pressure return hose on the power steering pump low pressure fitting. Be sure hose clamps are properly reinstalled. 6. Install the power steering fluid supply hose from the power steering fluid reservoir, on the power steering pump fluid fitting. Be sure hose is clear of accessory drive belts and all hose clamps are properly reinstalled. 7. Install the serpentine drive belt. 8. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 9. Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamps are properly reinstalled. Tighten the screw clamp to a torque of 2 Nm (18 inch. lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is required to keep the power steering hoses from becoming overheated. 10. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 11. Install the exhaust pipe on the exhaust manifold. Install all exhaust system hangers/isolators on the exhaust system brackets. 12. Connect the oxygen sensor wiring harness to the vehicle wiring harness. Install wiring harness grommet in the floor pan of the vehicle. 13. Install the accessory drive splash shield. 14. Lower vehicle. 15. Connect the negative battery cable on the negative battery post. 16. Perform the POWER STEERING PUMP INITIAL OPERATION service procedure listed to properly fill and bleed the power steering system. 17. Inspect for leaks. Removal NOTE: Before proceeding with this procedure, review the Service Precautions. REMOVAL 1. Remove the (-) negative battery cable from the battery and isolate cable. 2. Remove cap from power steering fluid reservoir. 3. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Disconnect the oxygen sensor wiring harness from the vehicle wiring harness. Access to connection at vehicle wiring harness is through the oxygen sensor wiring harness grommet in the floor pan of the vehicle. NOTE: The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pump from the vehicle. 6. Remove the catalytic converter from the exhaust manifold. Then remove all the exhaust system hangers/isolators from the brackets on the exhaust system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4891 7. Move the exhaust system as far rearward and to the left side of the vehicle as possible. Power Steering Return Hose At Return Line 8. Raise the heat sleeve on the power steering hoses to expose the hose to steel tube connection. Remove the hose from the power steering fluid return line on the front suspension cradle. Allow the remaining power steering fluid to drain from the pump and fluid reservoir through the removed return hose. 9. Remove the accessory drive splash shield. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4892 Serpentine Drive Belt And Routing 10. Remove the serpentine accessory drive belt from the engine. Power Steering Hoses 11. Remove the power steering fluid supply hose coming from the remote fluid reservoir, from the fitting on the power steering pump. Drain off excess power steering fluid from hose. 12. Remove the power steering fluid pressure line from the power steering pump. Drain excess power steering fluid from tube. 13. Remove the power steering fluid return hose from the power steering pump. Drain excess power steering fluid from tube. Power Steering Pump Support Bracket 14. Remove the support bracket at the rear of the power steering pump attaching the pump to the rear of the engine. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4893 15. Remove the 3 bolts mounting the power steering pump to the alternator/power steering pump and belt tensioner mounting bracket. 16. Remove the power steering pump from its mounting bracket. 17. The power steering pump is removed from the vehicle by pulling it out through the exhaust tunnel area in the floor pan of the vehicle. 18. If transferal of the power steering pump pulley is necessary, refer to Overhaul. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump Pulley Puller C-4333 Special Tool C-4333 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump Pulley Puller C-4333 > Page 4896 Special Tool C-4063B Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 4902 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to diagnose the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair REMOVAL Park Brake Release Handle 1. Remove screws holding parking brake release handle to instrument panel. Lower Steering Column Cover 2. Remove screws holding bottom of lower steering column cover to instrument panel. 3. Remove screw holding right side of lower steering column cover to instrument panel. Park Brake Release Handle Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 4906 4. Disengage park brake release cable case from groove on end of release handle. 5. Disengage cable end pivot from slot on release handle. INSTALLATION For installation, reverse the above procedures, Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area Technical Service Bulletin # 19-003-03 Date: 030829 Steering Column - Pop/Tick From Steering Wheel Area NUMBER: 19-003-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE CORRECTING VEHICLE BUILD DATES. SUBJECT: Pop/Tick Sound In Steering Wheel Area OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in the steering column upper tilt head. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 2001 - 2002 (RG) Chrysler Voyager (International Markets) 1999 - 2002 (WJ) Grand Cherokee 2001 - 2002 (WG) Grand Cherokee (International Markets) NOTE: **This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before Jan. 13, 2002 (MDH 0113XX).** NOTE: **For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7, 2003.** SYMPTOM/CONDITION: A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion. The sound is associated with input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as driving over an expansion strip. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure. NOTE: If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99 (Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this bulletin. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 4915 PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure 1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before beginning steering wheel removal procedure. WARNING: Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. 2. Remove and isolate the negative battery cable from the battery. 3. Remove the lower and upper steering column shrouds. 4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 5. Remove the steering wheel attaching nut. 6. Using the appropriate steering wheel puller, remove the steering wheel. 7. Remove the multi-function switch and its wiring connections. 8. Disconnect the clock spring wiring connection and remove the clock spring. NOTE: When removing the clock spring, do not change the orientation of the clock spring inner wheel. If the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered. Follow the procedure for clock spring centering in the appropriate service manual. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 4916 9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly. 10. Remove the snap ring from the steering shaft upper tilt head assembly. 11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing. 12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column. 13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering column. 14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing wedge. 15. Remove and discard the wave washer. 16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing wedge (Fig. 1). 17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.). 18. Install the upper bearing wedge to the tilt steering shaft. 19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring groove. This will facilitate snap ring installation. 20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the steering shaft outward and push the snap ring as far down the shaft as possible. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 4917 21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering shaft so the one edge of the tool is resting on the snap ring (Fig. 2). 22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool 05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into its groove on the steering shaft. NOTE: Do not over torque steering wheel nut. NOTE: Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool 05083385AA can be discarded. 23. Make sure that the snap ring is fully seated into its groove. 24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.). 25. Install the clock spring and its wiring connections. 26. Install the multi-function switch and its wiring connections. 27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.). 28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.). 30. Install the lower and upper steering column shrouds. 31. Connect negative battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area Technical Service Bulletin # 19-003-03 Date: 030829 Steering Column - Pop/Tick From Steering Wheel Area NUMBER: 19-003-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE CORRECTING VEHICLE BUILD DATES. SUBJECT: Pop/Tick Sound In Steering Wheel Area OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in the steering column upper tilt head. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 2001 - 2002 (RG) Chrysler Voyager (International Markets) 1999 - 2002 (WJ) Grand Cherokee 2001 - 2002 (WG) Grand Cherokee (International Markets) NOTE: **This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before Jan. 13, 2002 (MDH 0113XX).** NOTE: **For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7, 2003.** SYMPTOM/CONDITION: A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion. The sound is associated with input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as driving over an expansion strip. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure. NOTE: If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99 (Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this bulletin. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 4923 PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure 1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before beginning steering wheel removal procedure. WARNING: Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. 2. Remove and isolate the negative battery cable from the battery. 3. Remove the lower and upper steering column shrouds. 4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 5. Remove the steering wheel attaching nut. 6. Using the appropriate steering wheel puller, remove the steering wheel. 7. Remove the multi-function switch and its wiring connections. 8. Disconnect the clock spring wiring connection and remove the clock spring. NOTE: When removing the clock spring, do not change the orientation of the clock spring inner wheel. If the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered. Follow the procedure for clock spring centering in the appropriate service manual. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 4924 9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly. 10. Remove the snap ring from the steering shaft upper tilt head assembly. 11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing. 12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column. 13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering column. 14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing wedge. 15. Remove and discard the wave washer. 16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing wedge (Fig. 1). 17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.). 18. Install the upper bearing wedge to the tilt steering shaft. 19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring groove. This will facilitate snap ring installation. 20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the steering shaft outward and push the snap ring as far down the shaft as possible. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 4925 21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering shaft so the one edge of the tool is resting on the snap ring (Fig. 2). 22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool 05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into its groove on the steering shaft. NOTE: Do not over torque steering wheel nut. NOTE: Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool 05083385AA can be discarded. 23. Make sure that the snap ring is fully seated into its groove. 24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.). 25. Install the clock spring and its wiring connections. 26. Install the multi-function switch and its wiring connections. 27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.). 28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.). 30. Install the lower and upper steering column shrouds. 31. Connect negative battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4934 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4935 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4936 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4937 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4938 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4939 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions Steering Gear: All Technical Service Bulletins Steering - Steering Gear Removal/Installation Revisions NUMBER: 26-07-99A GROUP: Miscellaneous DATE: July, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the steering gear removal and installation procedures Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions > Page 4945 19-28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions > Page 4946 19-29 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions > Page 4947 19-30 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4952 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4953 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4954 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4955 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4956 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4957 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions Steering Gear: All Technical Service Bulletins Steering - Steering Gear Removal/Installation Revisions NUMBER: 26-07-99A GROUP: Miscellaneous DATE: July, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the steering gear removal and installation procedures Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions > Page 4963 19-28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions > Page 4964 19-29 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear Removal/Installation Revisions > Page 4965 19-30 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4966 Steering Gear: Specifications To Cradle Attaching Bolts .................................................................................................................... ................................................ 183 Nm (135 ft. lbs.) Coupler Pinch Bolt ............................................ .................................................................................................................................. 28 Nm (250 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4967 Steering Gear: Service Precautions WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings or power steering gear ports to prevent entry of foreign material into the components. NOTE: Do not use any type of automatic transmission fluid in the power steering system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4968 Steering Gear: Description and Operation Power Steering Gear Assembly NOTE: The power steering gear should NOT be serviced or adjusted. If a malfunction or oil leak occurs, the complete steering gear should be replaced. If a steering gear boot needs to be replaced due to damage, refer to the power steering gear for proper procedure. The power steering system consists of these four major components. Power Steering Gear, Power Steering Pump, Pressure Hose, and Return Line. Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As required steering effort increases, as in a turn, the torsion bar twists, causing relative rotary motion between the rotary valve body and the valve spool. This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort. The drive tangs on the pinion mate loosely with a stub shaft to permit manual steering control to be maintained if the drive belt on the power steering pump should break. However, under these conditions, steering effort will be increased. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal Steering Gear: Service and Repair Removal The content of this article reflects the changes called out by TSB 26-07-99. NOTE: - The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs, the complete steering gear assembly must be replaced. - Before proceeding with this procedure, review the Service Precautions. REMOVAL CAUTION: Positioning the steering column in the locked position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. With the ignition key in the locked position turn the steering wheel to the left until the steering wheel is in the locked position. 4. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler. 5. Raise vehicle on jack stands or centered on a frame contact type hoist. 6. Remove the front tires. Power Steering Return Hose At Return Line 7. Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube connection. Remove the return hose from the metal tube of the power steering fluid return line. Then allow the remaining power steering fluid to drain from the system through the hose and metal tube. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 4971 8. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Tie Rod End Removal From Steering Knuckle 9. Remove both tie rod ends from steering knuckles, using Puller Special Tool MB-990635 or MB-991113. HCU Bracket Attaching Bolts 10. Remove the 2 bolts and loosen the third attaching the antilock brakes hydraulic control unit (HCU) to the front suspension cradle. Then rotate the HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the HCU. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 4972 Front Suspension Cradle Plate and Attaching Bolts 11. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Then remove the cradle plate from the cradle. 12. If the vehicle is equipped with All Wheel Drive, remove the power transfer unit. Tube Bracket (FWD Shown) 13. Remove the bracket attaching the power steering fluid tubes to the front suspension cradle. Power Steering Fluid Pressure and Return Hoses at Steering Gear 14. Using a 18mm crowfoot, remove the power steering fluid pressure and return lines from the power steering gear. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 4973 15. Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle. NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear can not be removed from the vehicle with the intermediate coupler attached to the steering gear. Removing Roll Pin From Intermediate Coupler 16. Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin. Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing with the knurled nut. Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler. 17. Separate the intermediate coupler from the shaft of the steering gear. 18. Remove the steering gear assembly from the front suspension cradle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 4974 Steering Gear: Service and Repair Installation The content of this article reflects the changes called out by TSB 26-07-99. INSTALLATION 1. Install the steering gear up in the front suspension cradle, leaving room to install intermediate coupler. 2. Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear. Installing Roll Pin In Intermediate Coupler 3. Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut. Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler. 4. Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front suspension cradle mounting bolts and nuts. CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important. 5. Tighten the 3 steering gear to suspension cradle mounting bolts to a torque of 183 Nm (135 ft. lbs.). 6. Attach the power steering fluid pressure and return lines to the proper fittings on the steering gear. Tighten the power steering fluid line tube nuts to a torque of 31 Nm (275 in. lbs.). 7. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.). 8. If the vehicle is equipped with All Wheel Drive, install the power transfer unit. CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 4975 9. Install cradle plate on front suspension cradle and install the 10 cradle plate to cradle attaching bolts and nuts. Tighten all attaching bolts to a torque of 165 Nm (123 ft. lbs.). 10. Install the bracket attaching the power steering fluid tubes to the front suspension cradle. 11. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 12. Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamp is installed on return tube past the upset bead on the tube. Tighten the screw clamp to a torque of 2 Nm (18 in. lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is required to prevent the power steering hoses from being overheated. 13. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 14. Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 129 Nm (95 ft. lbs.). 15. Lower the vehicle to a level were the interior of vehicle is accessible. 16. Using the intermediate coupler, turn the front wheels of the vehicle to the left until the intermediate coupler shaft is properly aligned with the steering column coupler. Assemble the steering column shaft coupler onto the steering gear intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt. Tighten the pinch bolt nut to a torque of 28 Nm (250 in. lbs.). 17. Perform the POWER STEERING PUMP INITIAL OPERATION to properly fill and bleed the power steering system. 18. Inspect for leaks. 19. Adjust front toe. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 4976 Steering Gear: Tools and Equipment Remover Tie Rod End MB-991113 Special Tool 6831A Special Tool C-4975A Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Retaining Nut ....................................................................................................................................... ..................................................... 61 Nm (45 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Adjusting Sleeve Nut ........................................................................................................................... ..................................................... 75 Nm (55 ft. lbs.) To Steering Knuckle Nut .................................. ........................................................................................................................................ 54 Nm (40 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End Tie Rod End: Service and Repair Outer Tie Rod End REMOVAL 1. Loosen inner tie rod to outer tie rod jam nut. 2. Remove nut attaching outer tie rod end to steering knuckle. The nut is to be removed from tie rod end by holding tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 4986 Tie Rod End Removal From Steering Knuckle 3. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool, MB-991113 or MB-990635. 4. Remove outer tie rod end from inner tie rod by unthreading it from the inner tie rod. INSTALLATION NOTE: Before installing the outer tie rod end, make sure the jam nut is on inner tie rod. 1. Install outer tie rod end onto inner tie rod. 2. Do not tighten jam nut. 3. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket torque tie rod end attaching nut to 54 Nm (40 ft. lbs.). 4. Tighten tie rod jam nut to 55 Nm (75 ft. lbs.) torque. CAUTION: During this procedure do not allow the steering gear boot to become twisted. 5. Adjust the front toe setting on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 4987 Tie Rod End: Service and Repair Inner Tie Rod End The inner tie rod end is serviced with the rack and pinion assembly only. Chrysler does not provide a separate service procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation Ball Joint: Description and Operation Ball Joint Assembly The ball joint is pressed into the lower control arm. The ball joint has a non-tapered stud with a notch to provide clearance for the steering knuckle clamp bolt and to provide retention of the ball stud in the steering knuckle. The ball joint stud is clamped and locked into the steering knuckle leg using a pinch bolt. The ball joint is lubricated for life during the manufacturing process. Once lubricated for life, the grease fitting head is snapped off by the manufacturer. This is done to eliminate the possibility of lubrication latter during the ball joints life thus damaging the non-vented seal boot. The ball joint used on this vehicle is replaceable and if found defective can be serviced as a separate component of the lower control arm assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Page 4992 Ball Joint: Testing and Inspection With the weight of the vehicle resting on the road wheels, grasp the grease fitting (which from the manufacturer should have the head missing) on the bottom of the ball joint and with no mechanical assistance or added force attempt to rotate the grease fitting. If the ball joint is worn, the grease fitting will rotate easily. If movement is noted, replacement of the ball joint is recommended. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) Ball Joint: Service and Repair Ball Joint Replacement (Front Suspension) REMOVE Ball Joint Seal Boot Removal 1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly. Ball Joint Removal From Lower Control Arm 2. Position receiving cup, Special Tool 6758 to support lower control arm when removing ball joint assembly. Install Remover, Special Tool 6919 on top of the ball joint assembly. 3. Using the arbor press, press the ball joint assembly completely out of the lower control arm. INSTALL Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 4995 Installation Position Of Ball Joint In Control Arm NOTE: When installing ball joint in lower control arm, position the ball joint in control arm so notch in ball joint stud is in the direction shown. This will ease assembly of the ball joint to the steering when installing pinch bolt. 1. By hand, position ball joint into ball joint bore of lower control arm. Be sure ball joint is not cocked in the bore of the control arm, this will cause the ball joint to bind when being pressed into control arm. Installing Ball Joint In Control Arm 2. Position control arm with installed ball joint, in an arbor press with Receiving Cup, Special Tool 6758 supporting the lower control arm. Then center Installer, Special Tool 6908-4 on the bottom of the ball joint. Correctly Installed Lower Ball Joint 3. Carefully align all pieces. Then press the ball joint into the lower control arm until it is completely seated against surface of lower control arm. The ball joint is correctly installed when there is no gap between the ball joint and the lower control arm. Do not apply excessive force against the ball joint or the lower control arm. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 4996 CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the ball joint seal must be positioned as shown. 4. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to he with the shield positioned. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. 5. Place Installer, Special Tool 6758 over seal boot and squarely align it with bottom edge of seal boot. Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. CAUTION: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint using Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot. Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of the ball joint. - After the ball joint is properly greased, clip the end of the grease fitting off below the hex. The ball joint seal boot is non-purgeable and further greasing is not required and can result in damage to the seal boot. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 4997 Ball Joint: Service and Repair Seal Boot Replacement REMOVE Ball Joint Seal Boot Removal 1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly. INSTALL Ball Joint Seal Boot Installed Position CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the ball joint seal must be positioned as shown. 1. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 4998 2. Place Installer, Special Tool 6758 over seal boot and squarely align it with bottom edge of seal boot. Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. CAUTION: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint using Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot. Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of the ball joint. - After the ball joint is properly greased, clip the end of the grease fitting off below the hex. The ball joint seal boot is non-purgeable and further greasing is not required and can result in damage to the seal boot. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Control Arm Bushing: Service and Repair Front REMOVE 1. Remove the lower control arm from the front suspension cradle. 2. Securely mount the lower control arm in a vise. Tools Assembled For Removal Of Front Bushing 3. Assemble for removal of the front bushing, the Bushing Receiver, Special Tool 6908-2, Bushing Remover, Special Tool 6908-1, Nut, Special Tool 6908-3 thrust washer, threaded rod and small nut, as shown on the lower control arm and front bushing. 4. To remove front bushing from lower control arm, hold the threaded rod stationary and tighten the Nut, Special Tool 690-3. This will force the front bushing out of the lower control arm and into Bushing Receiver, Special Tool 6908-2. INSTALL 1. Securely mount the lower control arm in a vise. Installation Position Of Lower Control Arm Front Bushing NOTE: The lower control arm front bushing is a directional bushing. It must be installed in the lower control arm positioned. 2. Position the front bushing in the lower control arm so that the 2 rubber blocks on the bushing are positioned horizontally. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front > Page 5004 Tools Assembled For Installation Of Front Bushing 3. Assemble for installation of the front bushing, the Bushing Receiver, Special Tool 6908-5, Bushing Installer, Special Tool 6908-4, Nut, Special Tool 6908-3 thrust washer, threaded rod and small nut, on the lower control arm and front bushing. 4. To install the front bushing in lower control arm, hold the threaded rod stationary and tighten the Nut, Special Tool 6908-3. This will pull the front bushing into the lower control arm. Correctly Installed Lower Control Arm Bushing 5. Continue pulling the bushing into the lower control arm until bushing is seated squarely against the lower control arm and there is no gap between the bushing and the lower control arm. 6. Install the lower control arm on the front suspension cradle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front > Page 5005 Control Arm Bushing: Service and Repair Rear REMOVE 1. Remove the lower control arm from the front suspension cradle. 2. Mount the lower control arm in a vise without using excessive clamping force. Slit Lower Control Arm Rear Bushing 3. Using a sharp knife, (such as a razor) slit the bushing lengthwise to allow its removal from the lower control arm. 4. Remove the bushing from the lower control arm. INSTALL CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant specified to the control arm bushing. 1. Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing. This will aid in the installation of the bushing on the lower control arm. Correctly Installed Lower Control Arm Bushing 2. With the lower control arm held securely in a vise, install bushing on lower control arm. Install bushing by pushing and rocking the bushing until it is fully installed on lower control arm. Be sure when bushing is installed it is past the upset on the end of the lower control arm. 3. The rear bushing of the lower control arm, when correctly installed, is to be positioned on the lower control arm. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications Cross-Member: Specifications To Body Attaching Bolts ...................................................................................................................... ................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12 ............................................................................................................................................ 108 Nm (80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14 .......................................................................................................................................... 166 Nm (123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts ............................................................................................................................................... 165 Nm (123 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint Stud Nut/Bolt ........................................................................................................................ ............................................... 145 Nm (105 ft. lbs.) Wheel Stop ........................................................ ....................................................................................................................................... 95 Nm (70 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5012 Front Steering Knuckle: Description and Operation Front Steering Knuckle The steering knuckle is a single casting with legs machined for attachment of the strut damper, steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has the front hub and bearing mounted to it. The hub and bearing is positioned through the knuckle, with the drive shaft constant velocity stub shaft splined through the center of the hub. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5013 Front Steering Knuckle: Testing and Inspection The front suspension knuckle is not a repairable component of the front suspension. It must be replaced. If bent, broken, or damaged in any way, do not attempt to straighten or repair the steering knuckle. Service replacement of the front hub/bearing assembly can be done with the front steering knuckle remaining on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal REMOVAL 1. Raise vehicle on jack stands or centered on a frame contact type hoist. Hub And Bearing To Stub Axle Retaining Nut 2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire assembly from the vehicle. Wave Washer 4. Remove the wave washer from the end of the end of the stub axle. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5016 Front Disc Brake Caliper Attaching Bolts 6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts. Brake Caliper Mounting To Steering Knuckle 7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle. Correctly Supported Disc Brake Caliper 8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly. Do not allow the brake caliper assembly to hang by the brake flex hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5017 Remove/Install Brake Rotor 9. Remove the brake rotor from the hub and bearing assembly. Removing Tie Rod End Attaching Nut 10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench. Tie Rod End Removal From Steering Knuckle Arm 11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5018 Front Wheel Speed Sensor 12. Remove the front wheel speed sensor from the steering knuckle. Wheel Stop Location On Steering Knuckle 13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt when assembling the steering knuckle to the ball joint , the pinch bolt must be installed from the rear facing the front on the vehicle. Control Arm To Steering Knuckle Attachment 14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5019 Separating Ball Joint Stud From Steering Knuckle 15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported. Steering Knuckle Separation From Driveshaft 16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5020 Fig. 21 Strut To Steering Knuckle Mounting Bolt Removal 17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the steering knuckle from the strut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5021 Front Steering Knuckle: Service and Repair Installation INSTALLATION 1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to Hub And Bearing Assembly Service. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. Correctly Installed Eccentric Attaching Bolt CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket. 2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn. 3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly. 4. Install a new steering knuckle to ball joint stud, clamping bolt and nut. Tighten the clamping bolt and nut to a torque of 145 Nm (105 ft. lbs.). Torquing Tie Rod End Attaching Nut 5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.). 6. Install braking disc on hub and bearing assembly. 7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment. 8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake caliper assembly attaching bolts to a torque of 22 Nm (195 inch. lbs.). 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut. 10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor attaching bolt to a torque of 7 Nm (60 inch. lbs.). 11. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5022 12. Lower vehicle. Torquing Front Stub Axle To Hub Nut 13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 203 Nm (150 ft. lbs.) 14. Install the spring wave washer on the end of the stub axle. 15. Install the hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 16. Set front Toe on vehicle to required specification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Description and Operation Lateral Stabilizer Rod: Description and Operation Rear Track Bar On front wheel drive applications of this vehicle that are equipped with single leaf rear springs, a track bar is used on the rear axle. The track bar connects the rear axle to the frame/body of the vehicle. The track bar is isolated from the body of the vehicle by an isolator bushing located in each end of the track bar. The track bar prevents excessive side-to-side movement of the rear axle. The track bar is used to keep the location of the axle in the correct position for optimum handling and control of the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Track Bar Mount Lateral Stabilizer Rod: Service and Repair Track Bar Mount REMOVE 1. Remove the track bar from the track bar mount. Track Bar Mount 2. Remove the three bolts attaching the track bar mount to the body. INSTALLATION 1. For installation, reverse removal procedure. Tighten bolts to 61 Nm (45 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Track Bar Mount > Page 5028 Lateral Stabilizer Rod: Service and Repair Rear Track Bar Replacement REMOVAL Track Bar Mounting To Axle 1. Remove the nut and bolt mounting the track bar to the rear axle. 2. Remove the nut and bolt attaching the track bar to the track bar mount on the body of the vehicle. Remove the track bar from the track bar mount. INSTALLATION Track Bar Installation Track Bar Bolt Installation 1. Install the track bar first into the body mount for the track bar. Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle. Do not tighten. 2. Install the track bar into its mounting bracket on the rear axle. Install the track bar bolt with the head of the bolt facing toward the rear of the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Track Bar Mount > Page 5029 vehicle. Do not tighten. 3. Lower the vehicle to the ground until the full weight of the vehicle is supported by the wheels. Tighten both track bar attaching bolts to a torque of 95 Nm (70 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications Stabilizer Bushing: Specifications FRONT: Bushing Retainer Attaching Bolts ......................................................................................................................................................... 70 Nm (50 ft. lbs.) REAR: Bushing Retainer Attaching Bolts ......................................................................................................................................................... 61 Nm (45 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications > Page 5034 Stabilizer Bushing: Service and Repair If stabilizer bar to front suspension cradle bushings require replacement at time of inspection, install new bushings before installing stabilizer bar back on the vehicle. DISASSEMBLY 1. Stabilizer bar bushings are replaced by opening the slit on the bushings and peeling them off the stabilizer bar. ASSEMBLY 1. Install new bushings on stabilizer bar by spreading bushing at slit and forcing them onto stabilizer bar. Correctly Installed Stabilizer Bar To Cradle Bushing NOTE: Bushings must be installed on stabilizer bar so the square corner of the bushing will be down and slit in bushing will be facing the rear of the vehicle when the stabilizer is installed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound Stabilizer Link: Customer Interest Front Suspension - Knock/Squawk Sound NUMBER: 02-004-01 GROUP: Suspension DATE: July 6, 2001 SUBJECT: Knock/Squawk Sound From Front Suspension OVERVIEW: This bulletin involves installing new front sway bar link assemblies. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (RG) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: 1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low speed turn such as a parking lot maneuver. 2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy roads. DIAGNOSIS: 1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway bar link. Listen or feel for the condition described above while the wheel is being turned. If the condition is present, perform the Repair Procedure. 2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any loose, damaged or worn components and test drive vehicle. It the condition is still present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on a frame contact hoist. 2. Remove both front wheels. 3. Remove the upper and lower sway bar link nuts and remove the sway bar link. CAUTION: WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING A # 40 TORX BIT INTO THE END OF THE STUD. 4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.). 5. Perform steps 3 and 4 for the other sway bar link. 6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.) and then use a criss-cross pattern again to tighten to Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound > Page 5043 a final torque of 135 N.m (100 ft. lbs.). 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-03-00 > Feb > 00 > Front Strut - Knock/Clunk Sound Stabilizer Link: Customer Interest Front Strut - Knock/Clunk Sound NUMBER: 02-03-00 GROUP: Front Suspension DATE: Feb.25, 2000 MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) SUBJECT: knock/Clunk Sound From Front Strut Area OVERVIEW: This bulletin involves installing revised front sway bar link retaining nut/washer assemblies. SYMPTOM/CONDITION: A knocking/clunking sound coming from the front sway bar link is heard inside and outside the vehicle when driving over rough roads. DIAGNOSIS: Grasp and attempt to shake each front sway bar link. If either sway bar link feels loose check the upper attachments at the strut to determine if either washer is missing. If both upper washers are present, raise the vehicle to check the presence of both lower washers at the sway bar attachment. If any of the four washers are missing, perform the following Repair Procedure to replace all four nut & washer assemblies. PARTS REQUIRED: 4 06505291AA Assembly, Nut/Washer REPAIR PROCEDURE: 1. Raise the vehicle on a frame contact hoist. See Hoisting in the Lubrication and Maintenance section of the appropriate service manual if you are unfamiliar with the procedure. 2. Remove both front wheels. CAUTION: WHEN REMOVING THE NUTS FROM THE STUDS OF THE STABILIZER LINKS, DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD. USE OF A NON-PLUS IP BIT MAY RESULT IN ROUNDING OUT THE END OF THE STUD. 3. Remove each stabilizer link retaining nut/washer while holding the stabilizer link stud with a Torx Plus 40 IP bit, do not allow the stud to rotate in its socket. 4. Install revised nut/washer, p/n 06505291AA and tighten to 88 Nm (65 ft. lbs.). 5. Repeat steps 3 and 4 for the other three nut/washers. 6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 Nm (50 ft. lbs.) and then use a criss-cross pattern again to tighten to a final torque of 135 Nm (100 ft. lbs.) 7. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-20-10-96 0.7 Hrs. FAILURE CODE: P8- New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound Stabilizer Link: All Technical Service Bulletins Front Suspension - Knock/Squawk Sound NUMBER: 02-004-01 GROUP: Suspension DATE: July 6, 2001 SUBJECT: Knock/Squawk Sound From Front Suspension OVERVIEW: This bulletin involves installing new front sway bar link assemblies. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (RG) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: 1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low speed turn such as a parking lot maneuver. 2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy roads. DIAGNOSIS: 1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway bar link. Listen or feel for the condition described above while the wheel is being turned. If the condition is present, perform the Repair Procedure. 2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any loose, damaged or worn components and test drive vehicle. It the condition is still present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on a frame contact hoist. 2. Remove both front wheels. 3. Remove the upper and lower sway bar link nuts and remove the sway bar link. CAUTION: WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING A # 40 TORX BIT INTO THE END OF THE STUD. 4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.). 5. Perform steps 3 and 4 for the other sway bar link. 6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.) and then use a criss-cross pattern again to tighten to Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound > Page 5053 a final torque of 135 N.m (100 ft. lbs.). 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-03-00 > Feb > 00 > Front Strut - Knock/Clunk Sound Stabilizer Link: All Technical Service Bulletins Front Strut - Knock/Clunk Sound NUMBER: 02-03-00 GROUP: Front Suspension DATE: Feb.25, 2000 MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) SUBJECT: knock/Clunk Sound From Front Strut Area OVERVIEW: This bulletin involves installing revised front sway bar link retaining nut/washer assemblies. SYMPTOM/CONDITION: A knocking/clunking sound coming from the front sway bar link is heard inside and outside the vehicle when driving over rough roads. DIAGNOSIS: Grasp and attempt to shake each front sway bar link. If either sway bar link feels loose check the upper attachments at the strut to determine if either washer is missing. If both upper washers are present, raise the vehicle to check the presence of both lower washers at the sway bar attachment. If any of the four washers are missing, perform the following Repair Procedure to replace all four nut & washer assemblies. PARTS REQUIRED: 4 06505291AA Assembly, Nut/Washer REPAIR PROCEDURE: 1. Raise the vehicle on a frame contact hoist. See Hoisting in the Lubrication and Maintenance section of the appropriate service manual if you are unfamiliar with the procedure. 2. Remove both front wheels. CAUTION: WHEN REMOVING THE NUTS FROM THE STUDS OF THE STABILIZER LINKS, DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD. USE OF A NON-PLUS IP BIT MAY RESULT IN ROUNDING OUT THE END OF THE STUD. 3. Remove each stabilizer link retaining nut/washer while holding the stabilizer link stud with a Torx Plus 40 IP bit, do not allow the stud to rotate in its socket. 4. Install revised nut/washer, p/n 06505291AA and tighten to 88 Nm (65 ft. lbs.). 5. Repeat steps 3 and 4 for the other three nut/washers. 6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 Nm (50 ft. lbs.) and then use a criss-cross pattern again to tighten to a final torque of 135 Nm (100 ft. lbs.) 7. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-20-10-96 0.7 Hrs. FAILURE CODE: P8- New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 5058 Stabilizer Link: Specifications FRONT: Attaching Nuts ..................................................................................................................................... ................................................. 88 Nm (65 ft. lbs.) REAR: Attaching Nuts ..................................................................................................................................... ................................................. 61 Nm (45 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 5067 TIME ALLOWANCE FAILURE CODE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 5073 TIME ALLOWANCE FAILURE CODE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates Suspension Spring ( Coil / Leaf ): Technical Service Bulletins Electrical/Suspension - Service Manual Updates NUMBER: 26-03-99 GROUP: Miscellaneous DATE: March, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the Coil Spring Installation Procedures Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5078 2-29 Revisions to the Wiring Schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5079 8W-10-2A Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5080 8W-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5081 8W-10-16 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5082 8W-12-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5083 8W-20-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5084 8W-30-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5085 8W-30-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5086 8W-30-17 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5087 8W-30-18 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5088 8W-30-19 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5089 8W-30-21 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5090 8W-30-22 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5091 8W-33-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5092 8W-42-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5093 8W-62-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5094 8W-62-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5095 8W-62-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5096 8W-70-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5097 8W-80-28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5098 8W-80-57 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5099 8W-80-70 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5100 8W-80-71 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5101 Engine Compartment Connections - Late Build 8W-90-10A Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5102 8W-90-10 Revisions to the automatic transmission fluid and filter service procedures Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5103 21-1 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5104 21-16 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5105 21-17 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5106 Suspension Spring ( Coil / Leaf ): Technical Service Bulletins Suspension - Coil Spring Service Procedures Update NUMBER: 26-03-00E GROUP: Miscellaneous DATE: March, 2000 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Grand Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Updates to the coil spring service procedures Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5107 2-28 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 5108 Suspension Spring ( Coil / Leaf ): Specifications Spring Plate To Axle Attaching Bolts .................................................................................................................................................... 101 Nm (75 ft. lbs.) Rear Mount To Body Bolts .......................................................................................... ............................................................................ 61 Nm (45 ft. lbs.) Front Mount To Body Bolts ....... .............................................................................................................................................................. 61 Nm (45 ft. lbs.) To Front Hanger Mounting Nut ............................................................................................................................................................ 156 Nm (115 ft. lbs.) Shackle Plate Nuts ............................................................................................. ....................................................................................... 61 Nm (45 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Replacement Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement Removal REMOVAL 1. Raise vehicle on frame contact hoist to a comfortable working position. 2. Support axle with a jack stand. Pad should just contact axle. Rear Shock Mounting Bolt 3. Begin removal of the shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). 4. Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. Axle Plate Bolts 5. Loosen and remove the axle plate bolts from the rear axle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Replacement > Page 5111 Axle Plate 6. Remove the axle plate from the rear axle and the leaf spring. 7. Using the jack stands slowly lower the rear axle, permitting the rear springs to hang free. Leaf Spring Front Mount 8. Loosen and remove the 4 bolts from the front mount of the leaf spring. Rear Spring Hanger 9. Loosen and remove the nuts from the spring hanger for the rear leaf spring. Then remove the hanger plate from the hanger and remove the spring from the spring hanger. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Replacement > Page 5112 10. Remove the leaf spring from the vehicle. 11. Loosen and remove the pivot bolt from the front mount of the rear leaf spring. FRONT BUSHING REPLACEMENT 1. Install leaf spring in a proper holding fixture. 2. Install leaf spring press Special Tool C-4212-F. 3. Install adapter Special Tool C-4212-3. 4. Tighten leaf spring press until bushing is extracted from leaf spring. 5. Remove leaf spring press from leaf spring. 6. Insert replacement bushing into the leaf spring eye. Verify that the bushing flange is on the left side of the leaf spring when leaf spring is in the in vehicle installed position. 7. Install leaf spring press Special Tool C-4212-F. 8. Install adapter Special Tool C-4212-4. 9. Tighten leaf spring press until bushing flange bottoms solidly against leaf spring eye. 10. Remove leaf spring press and adapter. 11. Bend the bushing tabs so that they are contacting the leaf spring. Installation INSTALLATION 1. Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten. CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. 2. Raise front of spring and install four hanger bolts, tighten to 61 Nm (45 ft. lbs.) torque. 3. Install rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. 4. Verify lower leaf spring isolator is in position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Replacement > Page 5113 5. Raise axle into correct position on leaf spring with axle centered under spring locator post. 6. Verify that the leaf spring isolator is correctly positioned in the axle plate. 7. Install axle plate on the spring. 8. Install axle plate bolts. Tighten bolts to 101 Nm (75 ft. lbs.) torque. 9. Install shock absorber bolts. Do not tighten. 10. Lower vehicle to floor so that the full curb weight of vehicle is supported by the tires. 11. Tighten component fasteners as follows: - Front pivot bolt 156 Nm (115 ft. lbs.) - Shackle nuts 61 Nm (45 ft. lbs.) - Shock absorber bolts 101 Nm (75 ft. lbs.) 12. If the vehicle is not equipped with antilock brakes, raise vehicle and the connect the actuator for the height sensing proportioning valve on the rear leaf spring. Adjust the height sensing proportioning valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Replacement > Page 5114 Suspension Spring ( Coil / Leaf ): Service and Repair Mount Replacement Front REMOVAL Leaf Spring Front Mount 1. Loosen the pivot bolt attaching the front of the leaf spring to the spring mount. 2. Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand support the weight of the axle and leaf spring. 3. Remove the lower mounting bolt from the shock absorber. 4. Remove the bolts attaching the leaf spring front mount to the body of the vehicle. 5. Lower the leaf spring and remove the front mount from the spring. INSTALLATION 1. For installation, reverse removal procedure. Do not tighten front pivot bolt fully until vehicle is lowered and the full vehicle weight is applied to the rear wheels. Tighten leaf spring front mount bolts to 61 Nm (45 ft. lbs.). Tighten leaf spring front pivot bolt to 156 Nm (115 ft. lbs.). Rear REMOVE Leaf Spring Shackle Nuts (FWD) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Replacement > Page 5115 Rear Spring Hanger 1. Remove the attaching nuts and bolts from the leaf spring rear shackle. 2. Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand, support the weight of the axle and leaf spring. 3. Remove the lower mounting bolt from the shock absorber. Rear Spring Mount 4. Remove the bolts attaching the leaf spring rear mount to the body of the vehicle. 5. Lower the jackstand and the rear of the leaf spring. Remove the shackle from the leaf spring bushing. INSTALL CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the specified torque. This sequence must be followed to avoid bending the spring hanger. 1. For installation, reverse removal procedure. Do not tighten rear spring shackle nuts fully until vehicle is lowered and the full vehicle weight is applied to the rear wheels. Tighten rear spring mount bolts to 61 Nm (45 ft. lbs.). Tighten shackle nuts to 61 Nm (45 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise Technical Service Bulletin # 02-10-98 Date: 980925 Front Strut Bearings - Squeaking/Chirping Noise NO: 02-10-98 GROUP: Suspension DATE: Sept. 25, 1998 SUBJECT: Squeaking Noise From Strut Bearing(s) MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998. SYMPTOM/CONDITION: A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s) when turning the steering wheel or when the vehicle is driven over any irregularities in the road surface. DIAGNOSIS: With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180° apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower. Parts Information: AR (2) 04684418 Bearing, Strut Upper Pivot POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-39-93 One Side 0.9 Hrs. 02-05-39-94 Two Sides 1.6 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the strut upper pivot bearing(s). WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of the service manual, for the required lifting procedure to be used for this vehicle. 2. Remove the front wheel and tire assembly from the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5124 3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets (Figure 1). NOTE: WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2. 4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5125 6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the strut assembly from the vehicle (Figure 4). 7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment (PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed (Figure 5 and 6). WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. 8. Compress the coil spring until all coil spring tension is removed from the upper mount. 9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. 10. Remove the upper mount from the strut shaft. 11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight up. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5126 12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7). Be sure the pivot bearing is sitting flat on the spring seat once mounted. 13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat (Figure 6). Loosely install the retaining nut on the strut shaft. 14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.). 15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies. Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3). NOTE: IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING THE FRONT OF THE VEHICLE. 18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link to strut bracket attaching nut. NOTE: WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD (FIGURE 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5127 20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a torque of 88 Nm (65 ft. lbs.) (Figure 8). 21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.). 22. Install the wheel/tire assembly on the vehicle. 23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 24. Repeat step 2 through 23 for the other side strut, if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise Technical Service Bulletin # 02-10-98 Date: 980925 Front Strut Bearings - Squeaking/Chirping Noise NO: 02-10-98 GROUP: Suspension DATE: Sept. 25, 1998 SUBJECT: Squeaking Noise From Strut Bearing(s) MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998. SYMPTOM/CONDITION: A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s) when turning the steering wheel or when the vehicle is driven over any irregularities in the road surface. DIAGNOSIS: With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180° apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower. Parts Information: AR (2) 04684418 Bearing, Strut Upper Pivot POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-39-93 One Side 0.9 Hrs. 02-05-39-94 Two Sides 1.6 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the strut upper pivot bearing(s). WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of the service manual, for the required lifting procedure to be used for this vehicle. 2. Remove the front wheel and tire assembly from the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5133 3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets (Figure 1). NOTE: WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2. 4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5134 6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the strut assembly from the vehicle (Figure 4). 7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment (PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed (Figure 5 and 6). WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. 8. Compress the coil spring until all coil spring tension is removed from the upper mount. 9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. 10. Remove the upper mount from the strut shaft. 11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight up. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5135 12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7). Be sure the pivot bearing is sitting flat on the spring seat once mounted. 13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat (Figure 6). Loosely install the retaining nut on the strut shaft. 14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.). 15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies. Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3). NOTE: IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING THE FRONT OF THE VEHICLE. 18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link to strut bracket attaching nut. NOTE: WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD (FIGURE 8). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5136 20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a torque of 88 Nm (65 ft. lbs.) (Figure 8). 21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.). 22. Install the wheel/tire assembly on the vehicle. 23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 24. Repeat step 2 through 23 for the other side strut, if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Shock Absorber Mounting Bolts (All) ............................................................................................................................. ................................................. 101 Nm (75 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 5139 Suspension Strut / Shock Absorber: Specifications Struts Tower Attaching Nuts .......................................................................................................................... ............................................... 28 Nm (250 inch lbs.) Clevis Bracket To Steering Knuckle .................................................................................................................................. 88 Nm (65 ft. lbs.) Plus 1/4 Turn Shaft Nut ............................................................................................................... .................................................................................. 100 Nm (75 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front A MacPherson type strut assembly is used in place of the front suspension upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using 2 attaching bolts and nuts going through the strut clevis bracket and steering knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the threaded studs on the strut assemblies upper mount. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint) turn as an assembly. The strut assembly is used to dampen the front suspension and smooth ride of the vehicle. The strut assembly includes the following components: A rubber isolated upper mount, a pivot bearing, an upper spring seat, a jounce bumper, a dust shield, a coil spring, a lower isolator, and a strut (dampener). Each component is serviced by removing the strut assembly from the vehicle and disassembling it. COIL SPRING The strut and front suspension of the vehicle is supported by coil springs positioned around the upper half of each strut. The springs are contained between the upper and the lower seats of the strut assembly. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. During service procedures of the strut assembly, if both springs are removed, mark the springs to ensure installation in original position. Each coil spring comes with a plastic sleeve on the second coil of the spring. This plastic sleeve is a noise insulator for the coil spring. NOTE: If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5142 Suspension Strut / Shock Absorber: Description and Operation Shock Absorber REAR LOAD LEVELING A load-leveling shock is available. The self leveling shock absorbers are a self-contained vehicle leveling system and shock absorber combined. It does not require an external compressor, hoses, height leveling sensors, etc. It uses road inputs (bumps, stops, starts, turns, acceleration, deceleration, etc.) to activate pumping, which is just the extension and compression of the shock absorber. On the outside, it looks like a larger than normal shock absorber. Internally, it consists of a hydraulic pump and gas-spring cushion for leveling, as well as the normal shock absorbing mechanism. All the height leveling sensors, pump, etc., are contained inside the shocks. These load-leveling shock absorbers mount the same, but use longer fasteners than the standard shock absorbers. Although the fasteners are longer, the torque specifications are the same. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Page 5143 Suspension Strut / Shock Absorber: Testing and Inspection Strut Assembly Inspection 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged strut assembly dust boots. 3. Inspect the coil spring isolator on the lower spring seat, for any signs of damage or deterioration. Strut Assembly Leakage Inspection 4. Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement Suspension Strut / Shock Absorber: Service and Repair Replacement Removal REMOVAL WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly from location on front of vehicle requiring strut removal. 3. If both strut assemblies are to be removed, mark the strut assemblies right or left according to which side of the vehicle they were removed from. Brake Hose And Speed Sensor Cable Routing 4. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets. Stabilizer Bar Link To Strut Attachment NOTE: When removing nut from stud of stabilizer bar attaching link, do not allow stud to rotate. Hold stud from rotating by inserting a Torx Plus 401P bit in the end of the stud. 5. Remove the stabilizer bar attaching link from the bracket on the strut assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5146 Strut Damper Attachment To Steering Knuckle 6. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts. Strut Assembly To Strut Tower Attaching Nuts 7. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the strut assembly from the vehicle. 8. To disassemble and reassemble the strut assembly, refer to Overhaul. Installation INSTALLATION 1. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in shock tower. Install the 3 upper strut mount attaching nut/washer assemblies. Then using a crow foot tighten the 3 attaching nuts to a torque of 28 Nm (250 inch. lbs.). CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. 2. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts. If strut assembly is attached to steering knuckle using a cam bolt, the cam bolt must be installed in the lower slotted hole on strut clevis bracket. Also, attaching bolts should be installed with the nuts facing the front of the vehicle. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 3. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link to strut bracket attaching nut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5147 Torquing Stabilizer Bar Link To Strut Attaching Nut NOTE: When torquing nut on stud of stabilizer bar attaching link, do not allow stud to rotate. Hold stud from rotating by inserting a Torx Plus 401P bit in the end of the stud. 4. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40IP bit and crowfoot as shown to a torque of 88 Nm (65 ft. lbs.) 5. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets. Tighten the routing bracket attaching bolts to a torque of 13 Nm (10 ft. lbs.). 6. Install the wheel/tire assembly on the vehicle. 7. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). Rear REMOVAL 1. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. 2. Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the axle. NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by adjusting the support jack. If the lower shock absorber bolt deflects downward during removal, lower the axle by adjusting the support jack. 3. Remove the shock absorber lower mounting bolt. 4. While holding shock absorber, remove the shock absorber upper mounting bolt and shock absorber. INSTALLATION 1. While holding shock absorber in position against the frame rail, install the shock absorber upper mounting bolt. 2. Install the shock absorber lower mounting bolt securing the lower end of the shock absorber to the axle. 3. Remove the support jack. 4. Lower the vehicle to the ground so the full curb weight of the vehicle is supported by the suspension. 5. Tighten the upper and lower shock absorber mounting bolt to a torque of 101 Nm (75 ft. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5148 Suspension Strut / Shock Absorber: Service and Repair Overhaul Disassembly The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the tool manufacturer's instructions closely. DISASSEMBLY 1. If both struts are being serviced at the same time, mark the coil spring and strut assembly according to which side of the vehicle the strut was removed from, and which strut the coil spring was removed from. Strut Assembly In Compressor Upper Hooks Positioned 2. Position the strut assembly in the strut coil spring compressor following the manufacturers instructions. The strut clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed. WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5149 3. Compress the coil spring until all coil spring tension is removed from the upper mount. Retaining Nut Removal/Installation 4. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. 5. Remove the upper mount from the strut shaft. 6. If the upper pivot bearing needs to be serviced, remove it from the top of the coil spring upper seat by pulling it straight up. 7. Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring. NOTE: If the coil spring or upper mount need to be serviced, proceed with the next step, otherwise, proceed with step 10. 8. Release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the upper spring seat. 9. Remove the coil spring from the spring compresser. Dust Shield/Jounce Bumper 10. Remove the dust shield and jounce bumper as an assembly from the strut shaft by pulling both straight up and off the strut shaft. The dust shield cannot be separated from the jounce bumper until after it is removed from strut shaft. 11. Remove the jounce bumper from the dust shield. The jounce bumper is removed from the dust shield by collapsing the dust shield until the jounce bumper can be pulled free from the dust boot. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5150 Strut Lower Spring Seat Isolator 12. Remove the spring isolator from the lower spring seat on the strut. 13. Inspect the strut assembly components for the following and replace as necessary: - Inspect the strut for any condition of shaft binding over the full stroke of the shaft. - Check the upper mount for cracks and distortion and its retaining studs for any sign of damage. - Check the upper seat for severe deterioration of the rubber isolator. - Check for binding of the strut assembly pivot bearing. - Inspect the dust shield for rips and deterioration. - Inspect the jounce bumper for cracks and signs of deterioration. Assembly The content of this article reflects the changes called out by TSBs 26-03-99 and 26-03-00. ASSEMBLY NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with step 5. Coil Spring Positioned (Right Spring Shown) 1. Place the coil spring in the compressor following the manufacturers instructions. Proper orientation of the spring to the strut (once installed) is necessary. Consider the following when placing the coil spring in the compressor: From above, the compressor back is at the 12 o'clock position and you, standing in the front of the machine, are at the 6 o'clock position. For left side springs, place the lower coil spring end at the 7 o'clock position. For right side springs, place the lower coil spring end at the 5 o'clock position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5151 Upper Seat Notch Position 2. Install the upper seat on top of the coil spring. Position the notch in the perimeter of the upper seat toward the front of the compressor. 3. Position the upper hooks on top of the coil spring upper seat so the upper hooks span the outer shoulder of the upper seat. 4. Compress the coil spring. Pivot Bearing Installation 5. If the pivot bearing has been removed form the upper seat, install the pivot bearing on the top of the upper spring seat. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat. Be sure the pivot bearing is sitting flat on the spring seat once mounted. 6. Install the spring isolator on the lower spring seat of the strut. When installing the spring isolator, be sure the 2 retaining tabs on the spring isolator are installed in the 2 holes in the spring seat. When installed, the oversize holes in the spring seat should line up with the holes in the spring isolator. Jounce Bumper On Strut Shaft Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5152 7. Install the jounce bumper on the strut shaft. The jounce bumper is to be installed with the small end pointing downward. Installing Dust Shield 8. Install the dust shield on the strut. Collapse and stretch the dust shield down over the top of the jounce bumper until the dust shield snaps into the slot on the jounce bumper. Return the dust shield to its fully extended length. Strut Assembly In Compressor 9. Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. The clevis bracket on the strut should point straight outward away from the compressor (to the 6 o'clock position). Install the clamp on the lower end of the coil spring and strut, so the strut is held in place. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5153 Top View Lower Spring Seats Proper orientation of the coil spring to the strut is necessary. Verify the lower end of the coil spring is contacting the strut's lower spring seat at the proper location using the image as a guide. The strut's clevis bracket is pointing straight outward to the 6 o'clock position. For left side struts and springs, the lower coil spring end should contact the strut's lower spring seat at the 7 o'clock position. For right side struts and springs, the lower coil spring end should contact the strut's lower spring seat at the 5 o'clock position. 10. Install the strut mount over the strut shaft and onto the top of the pivot bearing and upper seat as shown. Loosely install the retaining nut on the strut shaft. 11. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.). 12. Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 13. Install strut assembly on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications To Frame Rail ...................................................................................................................................... ............................................... 33 Nm (290 inch lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Standard Suspension Travel Bumper: Service and Repair Standard There are two types of jounce bumpers available depending on which suspension option the vehicle is equipped with. REMOVAL-STANDARD Jounce Bumper-Standard The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a weld nut located on the frame rail. 1. Using the proper tool, remove the bolt attaching the jounce bumper to frame rail. 2. Remove the jounce bumper from the frame rail. INSTALLATION-STANDARD 1. For installation, reverse the removal procedure. Tighten the jounce bumper mounting bolt to a torque of 33 Nm (290 inch. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Standard > Page 5159 Suspension Travel Bumper: Service and Repair Heavy Duty REMOVAL-HEAVY DUTY Jounce Bumper-Heavy Duty The jounce bumpers are serviced as an assembly. The jounce bumpers screw into a weld nut located in the frame rail. Bumper Replacement 1. Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise. 2. Remove the jounce bumper from the frame rail. INSTALLATION-HEAVY DUTY 1. For installation, reverse the removal procedure. Tighten the jounce bumper to a torque of 33 Nm (290 inch. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications To Axle And Mounting Bracket Pivot Bolt .............................................................................................................................................. 95 Nm (70 ft. lbs.) Bracket To Body Attaching Bolt .............................................................................................................................................................. 61 Nm (45 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Spare Tire - Winch Precautions Spare Tire: Technical Service Bulletins Spare Tire - Winch Precautions BULLETIN NUMBER: 22-01-00 GROUP: Wheels & Tires DATE: Mar.24, 2000 SUBJECT: Spare Tire Winches MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN DOES NOT APPLY TO 1999 TOWN & COUNTRY VEHICLES BUILT PRIOR TO JULY 2, 1998. DISCUSSION: Beginning November 1,1999, the spare tire winch that is installed during vehicle assembly is determined by the size/type of spare tire the vehicle is built with. DO NOT switch the size/type of spare tire a vehicle is equipped with unless the spare tire winch is the correct one for the size/type of spare tire to be used. Replacement of the spare tire winch may be required. The spare tire winches are equipped with a secondary locking mechanism that may not function properly if a full size spare or T125 70D15 Compact Spare is stored on a T145 90D16 compact spare winch or vise-versa. The illustration shows the correct application and identification for 1999-2000 NS-vehicle spare tire winches: PARTS INFORMATION CAUTION: DO NOT SWITCH THE SIZE/TYPE OF SPARE TIRE A VEHICLE IS EQUIPPED WITH UNLESS THE SPARE TIRE WINCH IS CORRECT FOR THE NEW SIZE/TYPE OF SPARE TIRE AS CALLED OUT IN THE TABLE ABOVE. REPLACEMENT OF THE SPARE TIRE WINCH MAY BE REQUIRED. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 5176 Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5185 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5186 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5187 TIRE/WHEEL MATCH MOUNTING Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5188 WHEEL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5189 WHEEL BORE PILOT DIAMETERS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5190 HUB WHEEL PILOT DIAMETER Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5191 HUB WHEEL PILOT RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5192 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5198 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5199 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5200 TIRE/WHEEL MATCH MOUNTING Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5201 WHEEL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5202 WHEEL BORE PILOT DIAMETERS Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5203 HUB WHEEL PILOT DIAMETER Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5204 HUB WHEEL PILOT RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 5205 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance Weights Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights NO: 22-01-98 GROUP: Tires & Wheels DATE: Mar. 13, 1998 SUBJECT: Balance Weights For Aluminum Wheels MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town & Country/Caravan/Voyager DISCUSSION: Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance weight retention flange. This balance weight retention flange requires the use of special low profile balance weights. The new balance weights are made by Perfect Equipment Company LLC, and are available through their distributors and subsequent automotive jobbers. The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors listed: POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance Weights Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights NO: 22-01-98 GROUP: Tires & Wheels DATE: Mar. 13, 1998 SUBJECT: Balance Weights For Aluminum Wheels MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town & Country/Caravan/Voyager DISCUSSION: Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance weight retention flange. This balance weight retention flange requires the use of special low profile balance weights. The new balance weights are made by Perfect Equipment Company LLC, and are available through their distributors and subsequent automotive jobbers. The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors listed: POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5215 Wheels: Description and Operation Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for the specific wheel applications used on a vehicle and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design from the original equipment part. All aluminum wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Vehicles that are equipped with bolt-on wheel covers use large nose wheel nuts. The wheel nuts used on a vehicle equipped with bolt-on wheel covers are externally threaded so that the wheel covers can be attached to the wheel nuts. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. WARNING: INSTALLING WHEELS WITHOUT GOOD METAL-TO-METAL CONTACT COULD CAUSE LOOSENING OF WHEEL LUG NUTS. THIS COULD ADVERSELY AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5216 Wheels: Testing and Inspection Wheels must be replaced if they: Have excessive run out - Are bent, dented or cracked - Leak air - Have damaged wheel lug holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels are available through the dealer. When obtaining replacement wheels from any other source, they must be equivalent in load carrying capacity. The wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match the original equipment wheels. WARNING: FAILURE TO USE ORIGINAL EQUIPMENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE. - REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY OF THE RIM MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5228 Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque .................................................................................................................................... ................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ........................................................... ........................................................................................................................................................... 19 mm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5229 Wheel Fastener: Specifications Wheel Stud Size Mounting Stud Size ............................................................................................................................. ........................................................... M12 x 1.5 mm Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front REMOVAL CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CANNOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. The following procedure and special tools shown MUST BE used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. Disc Brake Caliper Mounting 3. Remove the front caliper assembly from the front steering knuckle assembly. 4. Remove front rotor from hub, by pulling it straight off wheel mounting studs. 5. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly, so the threads on the stud are even with end of lug nut. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 5232 Wheel Stud Removal From Hub/Bearing Assembly Install Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud. 6. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. When shoulder of wheel stud is past flange remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel stud from flange. INSTALLATION Installing Wheel Stud Into Hub And Bearing 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back over braking disc and align with caliper mounting holes on steering knuckle. Install the caliper adapter to steering knuckle attaching bolts and torque to 19 Nm (168 inch. lbs.). 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 6. Lower vehicle to the ground. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 5233 Wheel Fastener: Service and Repair Rear REMOVAL CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs cannot be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature hub and bearing failure. The following procedure and special tools shown MUST be used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the rear axle for replacement of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum. Removing Wheel Stud From Hub And Bearing 4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the threads on stud are even with end of lug nut. Install Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud. 5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. Remove lug nut from stud and remove wheel stud from flange. INSTALLATION Installing Wheel Stud Into Hub And Bearing 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 5. Lower vehicle to the ground. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation AIR CONDITIONING SWITCH SENSE-PCM INPUT When the air conditioning or defrost switch is put in the ON position and the low pressure switch, combination valve, and high pressure switch close, the PCM receives an A/C input. After receiving this input, the PCM activates the A/C compressor clutch by grounding the A/C clutch relay. The PCM also adjusts idle speed to a scheduled RPM to compensate for increased engine load. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Lamp Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel HVAC Control. Refer to Radio Bezel and HVAC Control Replacement. Rear Heater - A/C Switch Lamp Bulb 3. Rotate bulb socket counterclockwise one quarter. 4. Pull bulb socket from switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement > Page 5240 Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel and HVAC Control. Rear Heater - A/C Switch 3. Remove screw holding rear heater-A/C switch to radio bezel HVAC Control. 4. Disengage hook holding bottom of switch to radio bezel HVAC Control. 5. Remove switch from radio bezel HVAC Control. INSTALLATION For instrument, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration and Diagnostics Air Door Actuator / Motor: Testing and Inspection Actuator Calibration and Diagnostics NOTE: Do not run actuators unless they are properly mounted on the HVAC control module. Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as actuator travel falling within their minimum and maximum limits. Blend/Passenger Actuator Background The Blend/Passenger Actuator can move the temperature door in two directions. When the voltage at Pin 12 of the control module is high, about 11.5 volts, and the voltage at Pin 17 is low, about 1.5 volts, the door will move towards the Heat position. When Pin 17 is High and Pin 12 is Low the door will move towards the Cold position. When both Pins are high or both Pins are low, the actuator will not move. The Blend/Passenger feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Blend/Passenger actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door. Driver Actuator Background The Driver Actuator can move the temperature door in two directions. When the voltage at Pin 15 of the control module is high, about 11.5 volts, and the voltage at Pin 13 is low, about 1.5 volts the door will move towards the Cold position. When Pin 13 is High and Pin 15 is Low the door will move towards the Heat position. When both Pins are high or when both Pins are low, the actuator will not move. The Driver feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Driver Actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door. Mode Actuator Background The Mode actuator can move the mode door in two directions. When the voltage at Pin 18 of the control module is high, about 11.5 volts, and the voltage at Pin 12 is low, about 1.5 volts the door will move towards the Panel position. When Pin 12 is High and Pin 18 is Low the door will move towards the Defrost position. When both Pin are high or when both Pins are low, the actuator will not move. The Mode door feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.5 volts in the Panel position and 0.5 volts in the Defrost position. As the position of the Mode actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the mode door. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration and Diagnostics > Page 5246 Air Door Actuator / Motor: Testing and Inspection Actuator Calibration/Diagnostics and Cool Down Test GENERAL INFORMATION If the HVAC control module is replaced, the Calibration Diagnostic and Cooldown tests will need to be performed. Once this group of tests have successfully passed, they can be performed individually. The engine must be running during the test to provide hot coolant for the heater, A/C compressor operation and to assure that the actuators are calibrated correctly. The HVAC control module is capable of troubleshooting the system in approximately 120 seconds. If a condition is detected, an error code is displayed. The error code cannot be erased until the condition is repaired and the diagnostic test is performed. CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied. Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out of calibration. Actuator Calibration Radio Bezel And HVAC Control Radio Bezel And HVAC Control, Rear Blower Motor Switch And Zone Control Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the actuators, HVAC control module and its linkages. In vehicle calibration can be entered from the control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a failure occurred. Diagnostics will always occur during Calibration Diagnostic and Cooldown test. Diagnostics During the Actuator calibration, diagnostics are performed on the actuators and evaporator temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT LED's will flash to indicate either a successful calibration or the appropriate fail code(s). At this time manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash simultaneously showing that a failure has occurred. The control will not indicate the fail code, but only that a failure had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the Calibration Diagnostic and Cooldown test, after all repairs are completed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration and Diagnostics > Page 5247 Cooldown Test This test has been designed for performance testing of the A/C system at the manufacturing facility. If the HVAC control module is replaced, the Cooldown test will occur during Calibration test. Cooldown will not occur on Heater Only units. During the Cooldown test the control will monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature down a predetermined minimum amount in less than 2 minutes. Calibration/Cooldown LED Display Codes Calibration/Cooldown LED Display Codes See chart for definition of flashing LED's. If no problems are found, the control functions normally. Calibration/Diagnostics Test Entry To Initiate Tests: - Set Blower motor ON HIGH - Set Mode position to Panel - Open all A/C outlets - Set Temperature to Cold (Both slide pots if equipped) - Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LED's light) Results: - All LED's will turn on for 5 Seconds - Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing. Cooldown test is running if A/C and RECIRC are alternately flashing. - Acceptable results is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit. - After all tests have passed, Calibration Diagnostics and Cool down can be run separately. Cooldown Test Entry To Initiate Tests: - Set Blower motor ON HIGH - Set Mode position to Panel - Open all A/C outlets - Set Temperature to Cold (Both slide pots if equipped) - Depress WASH and A/C simultaneously for 5 Seconds NOTE: Prior to start of test, If the evaporator is already cold, the system will fail test. To correct, operate system with A/C OFF and the blower motor ON high for three minutes prior to starting test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration and Diagnostics > Page 5248 Results: - All LED's will turn on for 5 Seconds - Cooldown Test is running when A/C and RECIRC. are alternately flashing. If A/C and RECIRC. are flashing simultaneously, Cooldown has failed. Calibration Diagnostics And Cooldown Abort Test can be aborted by doing one of the following: - Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons. - Cycling Ignition OFF and then ON. - Control will automatically abort after 15 minutes from the time Calibration Diagnostics and Cooldown was entered. The HVAC control module will return to normal operation or may indicate unsuccessful Calibration. Diagnostics or Cooldown test by LED's flashing simultaneously. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Page 5249 Air Door Actuator / Motor: Adjustments 1. Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door actuator gear to master spline on door. 2. Install cam wheel. Align cam wheel track to FLOOR door actuator gear. 3. Align cam wheel slot with the post on the distribution housing marked "1". 4. Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master spline on PANEL door. Position actuator gear within cam wheel track. 5. Install DEFROST door actuator gear to housing. Match master spline of DEFROST door actuator to master spline on DEFROST door. Position actuator gear within cam wheel track. 6. Reinstall housing in vehicle. 7. Perform the HVAC control Calibration Diagnostic and Cooldown test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement REMOVAL Side View Of HVAC With Actuators The air conditioning system can be equipped with either a standard, single blend-air door actuator, or it can be equipped with dual actuators. The dual system has separate blend-air controls. This allows for separate control of the driver's side air, and the passenger side air. 1. Remove the lower left side steering column cover. Refer to Instrument Panel and Systems. ABS Control Module 2. Remove ABS control module. 3. Remove blend-air actuator connector. Blend-Air Actuator 4. Remove blend-air actuator. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5252 INSTALLATION 1. For installation, reverse the above procedures. 2. Perform the HVAC Control Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5253 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement REMOVAL 1. Remove the Instrument Panel. Refer to Instrument Panel and Systems for Replacement. ABS Control Module 2. Remove ABS control module. Mode Door Actuator Connector 3. Remove mode actuator connector. Mode Door Actuator 4. Remove mode door actuator. INSTALLATION Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5254 1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration Diagnostic and Cooldown test. REMOVAL 1. Remove A/C unit. 2. Place unit on bench. 3. Remove mode door actuator connector. 4. Remove mode door actuator mounting screws and remove actuator. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5255 Air Door Actuator / Motor: Service and Repair Recirculation Air Door Actuator Replacement REMOVAL 1. Pull back on carpeting on the right lower floor. 2. Remove Recirc. door actuator connector. Recirculation Door Actuator 3. Remove (3) mounting screws for Recirc. actuator. 4. Remove Recirc. actuator. 5. Disengage actuator linkage at Recirc. door. 6. Remove actuator from vehicle. INSTALLATION 1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration Diagnostic and Cooldown test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation Air Duct: Description and Operation SYSTEM OPERATION Air Distribution Ducts The air distribution ducts for the A/C, Heater, Defroster, and Second Seating Air Distribution are not serviceable in vehicle. The procedures for service of these ducts are covered in Instrument Panel and Gauges. The only ducts that are serviceable in the vehicle are the side window demister ducts and the ducts that feed the front door outlets for the first rear passenger(s) seating. Side Door Heater A/C Outlets Door Outlets The driver's and passenger side doors have supplemental air outlets and duct work. The air is channeled from the instrument panel to the door duct and either to the lower floor or upper door outlets. The air can be adjusted to blow on the first rear passenger seat(s). Side Window Demister Demister Inlet The side window demisters direct air from the heater assembly. The outlets are located on the top forward corners of the front door panels. The demisters operate when the control mode selector is on FLOOR, MIX or DEFROST setting. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement Air Duct: Service and Repair Air Distribution Duct (A/C) Replacement REMOVAL Quarter Trim Panel 1. Remove quarter trim panel, D-pillar, and headliner. 2. Remove screws securing D-pillar duct to quarter panel. Pull duct up and away from unit. Rear Crossover Duct 3. Remove screws securing duct to rear header. Upper A/C Duct 4. Remove screws securing duct to right and left rails. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement > Page 5261 INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement > Page 5262 Air Duct: Service and Repair Air Distribution Duct (Heater) Replacement REMOVAL Quarter Trim Panel Rear Heat-A/C Unit 1. Remove quarter trim panel and D-pillar. 2. Remove screws securing lower heat duct to housing. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement > Page 5263 Air Duct: Service and Repair Side Window Demister Duct Replacement REMOVAL AND INSTALLATION LEFT SIDE Left Side Demister Duct The LEFT side window demister duct is a two piece design. The left side has a long duct that attaches to an intermediate duct and then to the distribution housing. The duct is located on top of the instrument panel. To service the duct, remove the I/P cover and remove duct retainers/fasteners. RIGHT SIDE Right Side Demister Duct The demister duct on the right side is a one piece design. It is one long duct that attaches to the distribution housing. The duct is located on top of the instrument panel and it is not serviceable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair Air Register: Service and Repair REMOVAL Separate barrel from bezel by pulling outward. INSTALLATION For installation, push the outlet firmly into the opening until it locks into place. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5270 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor (Sensor Side) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5271 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Raise and support vehicle on safety stands. 3. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 4. Remove sensor from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection Blower Motor: Testing and Inspection Vibration and/or Noise Diagnosis The blower speed switch, in conjunction with the resistor block, supplies the blower motor with varied voltage. CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor with the resistor block removed from the heater A/C housing. Blower Motor Noise/Vibration Diagnosis Refer to the Blower Motor Vibration/Noise chart for diagnosis. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement Blower Motor: Service and Repair Blower Motor and Wheel Assembly Replacement REMOVAL 1. Remove glove box. Refer to Instrument Panel and Systems. Blower Motor Cover 2. Remove (4) hex head screws to blower motor cover. 3. Disconnect blower motor wiring. Wiring Grommet Feeding Wiring Through Housing 4. Remove grommet for wiring. Feed wiring through blower housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement > Page 5277 Blower Motor Screws 5. Remove mounting screws for blower motor. 6. Allow the blower assembly to drop down, and remove assembly from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement > Page 5278 Blower Motor: Service and Repair Blower Motor Wheel Replacement REMOVAL AND INSTALLATION The blower motor wheel is not serviced separately If the wheel needs to be replaced it is serviced as an assembly of the blower motor. For service procedure information, refer to Blower Motor Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement > Page 5279 Blower Motor: Service and Repair Rear Blower Motor Replacement REMOVAL 1. Remove the right quarter trim panel and D-pillar trim. Blower Motor 2. Remove (5) screws securing the blower motor housing to the rear of the HVAC housing (one screw located on evaporator cover). 4. Disconnect blower motor wiring connector. INSTALLATION For installation reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Component Locations Blower Motor Relay: Component Locations Power Distribution Center -- Sheet 8w-10-2 Rear Blower Relay Rear Blower Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5284 This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5285 Blower Motor Relay: Connector Locations Power Distribution Center Front Blower Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay Blower Motor Relay: Description and Operation Front Blower Motor Relay Circuit Operation Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1. The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power Distribution Center (PDC). The coil side of the relay is energized when the ignition switch is in the RUN position only. Power for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the relay Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit A22. Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl panel. Ground for the blower motor is controlled through the blower motor resistor and the blower motor switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay > Page 5288 Blower Motor Relay: Description and Operation Rear Blower Relay Circuit Operation Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear blower motor passes through the temperature sensor and one or more resistors, depending on speed selection. Two switches operate the rear blower motor by supplying ground; the front control switch and the rear control switch. The front control switch must be in the ON position for the rear control switch to operate the rear blower motor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Connector Locations Resistor Block Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5292 Blower Motor Resistor: Description and Operation SYSTEM OPERATION Rear Blower Resistor Block The rear blower motor resistor is not serviceable separately. The resistor is integral to the blower motor. If resistor is faulty, it is necessary to replace the complete blower motor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5293 Blower Motor Resistor: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate negative battery cable. Resistor Block Location 3. Locate and remove the wire connector from the blower resistor block. Block is located at the back of the engine compartment on the passenger side of the vehicle under the wiper module. NOTE: It may not necessary to remove the wiper module to access the resistor block. Resistor Block Removal 4. Using a long flat blade screwdriver, gently push in on drivers side of resistor. Be careful to catch the inner release tang and gently pry outward. WARNING: THE RESISTOR BLOCK MAY BE HOT. DO NOT ATTEMPT TO SERVICE THE RESISTOR BLOCK IF THE SYSTEM HAS BEEN RUNNING RECENTLY. LET THE SYSTEM COOL DOWN BEFORE REPAIRS ARE INITIATED. 5. Remove resistor block by inserting a flat blade pry tool on the side of the resistor block and pushing inward. Two guide lines are shown on the right hand edge of the resistor block to help guide the blade position. This will release the clips on the side of the resistor block. Pull resistor block out. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5294 INSTALLATION For installation, reverse the above procedures. Make sure the "TOP" lettering is on the top of the resistor. The coils on the Resistor Block should not be contacting one another. Before installation, gently separate the coils (with fingers only) if one coil is contacting another. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION Rear Blower Speed Switch The rear blower speed switch controls the rear blower with the choice of low and high speeds. when the switch is on it allows the blower speed switch located on the rear headliner to control rear blower speed. This switch will override the rear headliner blower switch. For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from the A/C control module. For service procedures, refer to Instrument Panel And Gauges. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications Compressor Clutch: Electrical Specifications Draw 2.2 amps @ 12 V ±0.5V @ 70°F Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications > Page 5303 Compressor Clutch: Mechanical Specifications Clutch Air Gap ..................................................................................................................................... ........................... 0.41 - 0.79 mm (0.016 - 0.031 in.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5304 A/C Compressor Clutch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5305 Compressor Clutch: Service and Repair REMOVAL AND INSTALLATION After a new clutch has been installed, check the voltage and amperage to the clutch (determine it to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams A/C Compressor Clutch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5309 Compressor Clutch Coil: Testing and Inspection The air conditioning compressor clutch electrical circuit is controlled by the Powertrain Control Module. It is located in the engine compartment outboard of the battery If the compressor clutch does not engage verify refrigerant charge. If the compressor clutch still does not engage check for battery voltage at the pressure transducer located on the liquid line. If voltage is not detected, refer to: - Powertrain Diagnostic Procedures for diagnostic information. If voltage is detected at the pressure transducer, connect pressure transducer and check for battery voltage between the compressor clutch connector terminals. If voltage is detected, perform A/C Clutch Coil Tests. Tests 1. Verify battery state of charge. (Test indicator in battery should be green). 2. Connect an ampmeter (0-10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0-20 volt scale) with clip leads measuring voltage across the battery and A/C clutch. 3. With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle. 4. The A/C clutch should engage immediately and the clutch voltage should be within two volts of the battery voltage. If the A/C clutch does not engage, test the fuse. 5. The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch coil. This is with the work area temperature at 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. 6. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4 amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed circuit for excessive voltage drop. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5310 Compressor Clutch Coil: Service and Repair REMOVAL Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Clutch Plate And Shim(s) 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5311 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has contaminated the faces of the pulley or front plate, they should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly. CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part. This will result in clutch slippage due to insufficient contact area. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten with the wire clip screw. 2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing outward. Also both snap ring eyelets must be to the right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the groove. CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5312 Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. CAUTION: Do not mar the pulley frictional surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the snap ring to make sure it is properly seated in the groove. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 1 mm (0.040 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s), measure the air gap between front plate and pulley face with feeler gauges. The air gap should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or subtract shims until desired air gap is obtained. 8. Install compressor shaft bolt. Tighten to 16.5 ± 2 Nm (155 ± 20 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5317 Power Distribution Center -- Sheet 8w-10-2 The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment next to the battery. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5318 Compressor Clutch Relay: Connector Locations Power Distribution Center A/C Compressor Clutch Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5319 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT The PCM operates the air conditioning clutch relay ground circuit, The radiator fan control module supplies battery power to the solenoid side of the relay. The air conditioning clutch relay will not energize unless the radiator fan control module energizes. The radiator control module energizes when the air conditioning or defrost switch is put in the ON position and the low pressure switch, combination valve, and high pressure switch close. With the engine operating, the PCM cycles the air conditioning clutch on and off when the A/C switch closes with the blower motor switch in the On position. When the PCM senses low idle speeds or wide-open-throttle through the throttle position sensor, it de-energizes the A/C clutch relay. The relay contacts open, preventing air conditioning clutch engagement. The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment next to the battery. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation SYSTEM OPERATION Condensate Drain Condensation from the evaporator housing is drained through the dash panel and on to the ground. This drain must be kept open to prevent water from collecting in the bottom of the housing. If the drain is blocked condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensate drainage below the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Front A/C Condenser Condenser HVAC: Service and Repair Front A/C Condenser WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL 1. Recover A/C system refrigerant. Liquid Line 2. Remove liquid line at filter-drier. Filter-Drier 3. Remove (2) bolts attaching filter-drier to radiator module. 4. Remove upper radiator crossmember. 5. Tilt radiator rearward. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Front A/C Condenser > Page 5325 Upper Discharge Line 6. Remove upper discharge line at condenser. 7. Through fascia, remove lower liquid line from filter-drier. 8. Remove (2) lower condenser mounting bolts. 9. Remove (2) upper mounting bolts. Condenser Removal 10. Remove condenser from vehicle. INSTALLATION NOTE: Inspect Cooling Module for presence of seals. Verify seals are available for re-installation. 1. Before installation, replace all O-rings and gaskets, coat all sealing surfaces with approved wax-free refrigerant oil. Then, reverse the above procedures, 2. Torque the following components to specifications: - Liquid line at filter/drier - 45 in. lbs. ± 10. - Upper discharge line at condenser - 180 in. lbs. ± 20. - Lower liquid line to condenser - 180 in. lbs. ± 20. - (2) lower, condenser mounting bolts - 45 in. lbs. ± 10. - (2) upper, condenser mounting bolts - 45 in. lbs. ± 10. - Tube fitting - 65 in. lbs. ± 5. 3. Evacuate and charge system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Front A/C Condenser > Page 5326 Condenser HVAC: Service and Repair Rear A/C Auxiliary Condenser If vehicle is equipped with rear heater and air conditioning, it will be equipped with an auxiliary condenser. The auxiliary condenser is mounted on the primary condenser in front of the radiator. Both condenser must be removed as an assembly and then separated. WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. The condenser assembly must first be removed from vehicle. Refer to CONDENSER ASSEMBLY Replacement for service procedures. REMOVAL 1. After condenser assembly removal, place on bench for disassembly. 2. Remove (1) bolt to liquid line on auxiliary condenser. Rear Heat-A/C Auxiliary Condenser 3. Remove (4) attaching bolts and separate auxiliary from primary condenser. INSTALLATION 1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved wax-free refrigerant oil. Then, reverse the above procedures. 2. Verify seals are in place on either side and on top of the radiator. 3. Evacuate and recharge system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Electrical Systems - Feature Changes Control Assembly: Technical Service Bulletins Electrical Systems - Feature Changes NO: 08-34-98 Rev. B GROUP: Electrical DATE: Oct. 9, 1998 SUBJECT: 1999 Electrical Feature Changes THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-34-98 REV. A, DATED JUL. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE REMOTE KEYLESS ENTRY (RKE) KEY FOB/TRANSMITTER PROGRAMMING PROCEDURE AND ADDITIONAL INFORMATION ABOUT THE HEAT VENTILATION AIR CONDITIONING (HVAC) CONTROL HEAD AND POWER DISTRIBUTION CENTER (PDC). MODELS: 1999 (NS) Town & Country/Caravan/Voyager DISCUSSION: The HVAC control head, "gold dust" instrument cluster, and remote radio control features were introduced in March of 1998 on the 1999 Town & Country Limited. All other features listed entered vehicle production July 2, 1998 (MDH 0702XX). Ignition Off Draw (IOD) Fuse Installation Previously the IOD fuse was taped under the PDC cover. Starting with the 1999 model year, the IOD fuse will be located in a spare IOD fuse holder cavity next to the IOD fuse location. Prior to the vehicle being delivered to the customer, the fuse from the spare cavity must be installed into the IOD fuse slot in order for the M1 feed to be active. Remote Radio Controls (RDZ) The Body Control Module (BCM) monitors steering wheel radio switch status (volume up/down, seek up/down, and preset station change). The BCM then communicates this information to the radio over the CCD bus. Remote Keyless Entry (RKE) Peanut Key Fob/Transmitter A new key fob and RKE module are used. Pinout for the RKE module is the same as 1998. **RKE and RKE programming is inhibited when the gearshift lever is not in Park.** The system assures no duplicate transmissions. This prevents unauthorized individuals from recording the transmitted signal and coming back later, playing back the "stolen" signal and thus gaining access to the vehicle. The key fob/transmitter programming procedure has changed and is as follows, **if an already programmed key fob/transmitter is available, otherwise a scan tool (DRBIII(R)) must be used to access the programming mode** 1. **With the transmission in Park**, turn the ignition switch to the ON position. 2. Press and hold the Unlock button **of an already programmed key fob/transmitter** for a minimum of **5** seconds to a maximum of 10 seconds. During the Unlock button **5**-10 second time frame press the Panic button, then release both buttons at the same time. The RKE system is now in the program mode for **30 seconds. A short chime will come from the BCM indicating the programming mode has been activated.** 3. Program the key fob/transmitter one by pressing and releasing the lock and unlock buttons at the same time, then press and release any button on the key fob/transmitter. **A short chime will sound indicating a key fob/transmitter has been successfully programmed.** 4. Perform step 3 on **any remaining key fob/transmitters within the 30 second** time frame. 5. The RKE system will exit the programming mode after **30 seconds** or if the ignition is turned OFF. **A chime will sound after 30 seconds has elapsed or if the ignition switch is turned OFF indicating the programming mode has been exited.** HVAC Control Head The HVAC control head communicates on the CCD bus and receives the A/C head pressure message from the Powertrain Control Module (PCM). The control head automatically resets to fresh air at ignition ON to help reduce odor. Vehicles are shipped from the assembly plant with the recirculation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Electrical Systems - Feature Changes > Page 5331 control programmed to cancel the recirculation mode when the ignition key is turned OFF and will reset to fresh/outside air mode when the ignition key is turned ON. The frequent use of outside air helps to keep odors from building up within the A/C-heater housing. It is recommended the recirculation mode be used as little as possible, especially in humid climates. For vehicle operators in hot and dry climates or people who are allergic to pollen and find frequent use of the recirculation mode necessary, the recirculation control can be programmed to not automatically reset to the fresh/outside air mode by using the following procedure: 1. Start the engine and turn the A/C blower switch to any position other than the OFF or LOW speed position. 2. Set the mode control to panel/face. 3. Turn the ignition key to the OFF position. 4. Depress and hold the recirculation button in. 5. Start the engine, continue to hold the recirculation button in. 6. The recirculation indicator light will flash repeatedly, when the light stops flashing release the recirculation button. Programming is now complete. If the light stays ON, the system will "remember" the recirculation mode when the ignition is turned ON. If the light goes OFF, the system will reset to fresh/outside air each time the ignition is turned ON. The HVAC control head has an automatic calibration feature **which activates after the ignition is turned ON and if the control head determines via the CCD bus, the VIN is different than the VIN the control head previously detected, such as when a new control head is being installed or a control head is being swapped from one vehicle to another.** The automatic calibration process takes about 45 seconds to complete. Rear Wiper CCD Driven The HVAC control head communicates rear wiper switch status over the CCD bus to the Body Control Module (BCM). Autostick Available On Dodge ES The Autostick feature allows the driver to control the vehicles transmission upshifts and downshifts by toggling a switch located near the end of the gearshift lever. The system also incorporates an Overdrive (O/D) OFF button at the end of the gearshift lever that allows the driver to switch between Overdrive ON and Overdrive OFF **when the gearshift lever is in the "D" position.** Instrument Clusters Autostick Cluster A unique cluster has been introduced to support the new Dodge ES model with Autostick. The cluster content and appearance is the same as the premium cluster (shown in the owners manual) except for the unique gear select indicator display. The gear select indicator display changes from the typical "P-R-N-D-3-L" to "P-R-N-D-1-2-3-4" for Autostick. Town & Country Limited Cluster A unique cluster has been introduced to support the new Chrysler Town & Country Limited model. The cluster content is the same as the premium cluster except for its unique appearance. The cluster offers a "gold dust" gauge appearance with red gauge pointers during daylight conditions. At night, the numbers, letters and/or symbols are illuminated using traditional blue-green lighting. Electrical Connector New Cluster Wiring Connector A new 13-way connector system is used for all NS instrument clusters. The connector on the wire harness side includes a Connector Position Assurance (CPA) secondary latch (orange), which assures the connector will not become dislodged (or loose) when seated properly. The connector includes blade type terminals, which offer greater strength and reduces the potential for bent terminals. NOTE: TO DISCONNECT THE WIRE HARNESS CONNECTOR FROM THE CLUSTER THE CPA LATCH ON THE WIRING HARNESS CONNECTOR MUST BE UNLOCKED BEFORE DEPRESSING THE RELEASE LATCH. New Connectors for All Door and Rear Quarter Speakers There are new speaker connectors for all door and rear quarter speakers. The new connectors provide a direct connect (versus pigtail). This improves the manufacturing process and reduces risk of rattles. Fog Lamps Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Electrical Systems - Feature Changes > Page 5332 A direct wiring connection to fog lamps (no pigtail) is now used. Ignition Coil The primary connector has been changed from a pin/sleeve type to a blade type connector for improved reliability. EATX Transmission Range Sensor (TRS) A new blade type TRS connector **will be used for 1999 as a running change. Early production 1999 vehicles will use the 1998 type sensor with a jumper harness.** O2 Sensor This includes a gold terminal and an isolated return signal to the PCM (pin 27). This change improves reliability. Wiper Motor The connector is changed from a 10-way to a 4-way. Stamped Battery Cable Terminal The new battery cable terminal requires less torque. The new torque specification is 3.3 - 4.5 Nm (30 - 40 in. lbs.). BCM Wiring Change Air Bag Warning Chime The BCM will sound a single chime if both of the following conditions are met: 1. Ignition has been in run/start position greater than 10 seconds. 2. The air bag lamp status message (sent from the air bag module) indicates lamp on. In order for the chime to be able to sound again (reset monitor), the BCM must receive input indicating the vehicle speed is zero and the air bag lamp is off. **Power Distribution Center (PDC) As a running change, expected to take place the first week of January 1999, a revised PDC will go into vehicle production. Although some fuse, relay, and connector positions will be different, the pin-outs and diagnostics for the individual connectors/components will remain the same.** POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5333 Control Assembly: Locations HVAC Control Module The control module is included in the A/C control head located on the instrument panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5334 Control Assembly: Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5335 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5336 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5337 Control Assembly: Description and Operation HVAC Control Module HVAC Control Module The HVAC control module regulates the operation of the various actuator motors. The actuator motors are used to move the mode, blend-air, and Recirculation doors. The control module is included in the A/C control head located on the instrument panel. The control head includes the blower speed switch, rear wiper and washer operation, front & rear window defogger, recirculation door operation, and A/C compressor operation if equipped. NOTE: The Recirculation function on the HVAC control module automatically defaults to the OFF position after a ignition key cycle. To reactivate the Recirculation function, the Recirculation button must be repressed. NOTE: The rear blower speed switch is serviced separately from the control head. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit Control Assembly: Testing and Inspection Calibration -- May Be Needed After Replacing Control Unit GENERAL INFORMATION If the Heating Ventilation and Air Conditioning (HVAC) control module is replaced, the Calibration Diagnostic and Cooldown tests will need to be performed. Once this group of tests have successfully passed, they can be performed individually. The engine must be running during the test to provide hot coolant for the heater, A/C compressor operation and to assure that the actuators are calibrated correctly. The HVAC control module is capable of troubleshooting the system in approximately 120 seconds. If a condition is detected, an error code is displayed. The error code cannot be erased until the condition is repaired and the diagnostic test is performed. Check wiring before replacing components. CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied. Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out of calibration. Radio Bezel and HVAC Control Radio Bezel and HVAC Control w/Rear Blower and Zone Control ACTUATOR CALIBRATION Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the actuators, HVAC control module and its linkages. In vehicle calibration can be entered from the control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a failure occurred. Diagnostics will always occur during Calibration Diagnostic and Cooldown test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 5340 DIAGNOSTICS During the Actuator calibration, diagnostics are performed on the actuators and evaporator temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT LED's will flash to indicate either a successful calibration or the appropriate fail code(s). At this time manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash simultaneously showing that a failure has occurred. The control will not indicate the fail code, but only that a failure had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the Calibration Diagnostic and Cooldown test, after all repairs are completed. COOLDOWN TEST This test has been designed for performance testing of the A/C system at the manufacturing facility. If the IWAC control module is replaced, the Cooldown test will occur during Calibration test. Cooldown will not occur on Heater Only units. During the Cooldown test the control will monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature down a predetermined minimum amount in less than 2 minutes. CALIBRATION / COOLDOWN LED DISPLAY CODES Calibration / Cooldown LED Display Codes See chart for definition of the flashing LED's noted before ignition cycled off. If no problems are found, the control functions normally. NOTE: Calibration is run automatically whenever the control head detects a "new" VIN number. Calibration may be initiated manually by pressing and holding WASH and REAR WIPER buttons for 5 seconds. COOLDOWN TEST ENTRY To Initiate Test: Set Blower motor ON HIGH - Open all A/C outlets - Depress A/C and WASH buttons simultaneously for 5 seconds (until all LED's light) Results: All LED's will turn on for 5 seconds - Cooldown test is running if A/C and RECIRC are alternately flashing - Acceptable result is when LED flashing stops - Calibration Diagnostics and Cooldown must be run separately CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT Test can be aborted by doing one of the following: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 5341 - Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons. - Cycling Ignition OFF and then ON. Control will automatically abort after 15 minutes from the time Calibration Diagnostics and Cooldown was entered. The HVAC control module will return to normal operation or may indicate unsuccessful Calibration Diagnostics or Cooldown test by LED's flashing simultaneously. COOLDOWN TEST FAILURE Determine if the refrigerant system is operating correctly: Check the outlet air temperature - Feel the compressor suction plumbing, is it hot? 1. If not OK, go to Step 2. If OK, repeat the Calibration Diagnostic and Cooldown test. 2. If system does not seem to be operating correctly, perform diagnostics for poor performance: - Low refrigerant charge - No charge - Compressor not operating Verify that the test was done with the evaporator at room temperature. The test consists of starting the compressor and measuring the time it takes for the evaporator temperature to fall 7 °C (20 °F). If the compressor has been running, the evaporator is cold already and will not be capable of falling 7 °C (20 °F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the Calibration Diagnostic and Cooldown test. If refrigerant system is performing properly and the system will not pass test. Repeat the Calibration Diagnostic and Cooldown test to determine if the evaporator temperature FIN sensor has developed an open or a short circuit. If the HVAC control module still passes Calibration test, verify Cooldown test manually with a pocket thermometer. The outlet air temperature must drop at least 7 °C (20 °F) within two minutes. If the vehicle passes with the manual thermometer, use the DRB Ill® viewing the evaporator probe temperature readout, and repeat the Cooldown test. Ensure the evaporator is at room temperature before starting test. Check if evaporator probe will drop the temperature 7 °C (20 °F) in two minutes. If the Evaporator Probe is found to be faulty, check that the sensor is positioned in the evaporator fins properly. If not, correct and repeat test. If OK, replace the evaporator probe. Once the repairs are completed, repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the DTC's. EEPROM DATA Calibration Diagnostics, Cooldown Status and evaporator temperature Fin Sensor values are stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control module uses this information: To determine if Cooldown needs to run - For proper position of the Heater-A/C unit assembly doors ACTUATOR CALIBRATION AND DIAGNOSTICS NOTE: Do not run actuators unless they are properly mounted on the HVAC control module. Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as actuator travel falling within their minimum and maximum limits. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 5342 Control Assembly: Testing and Inspection HVAC Control Diagnostic Conditions After calibration, Rear Wiper LED flashing once, Intermittent LED not flashing. The system has passed calibration. Press the Rear Wiper button to exit calibration. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing once. The mode actuator did not reach defrost position. 1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the defrost to panel position, and check Pin 6 voltage it should change from 0.5 - 1 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 3. If not OK, repair as necessary 3. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing twice. The mode actuator did not reach panel position. 1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from panel to defrost position , and check Pin 6 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1 volts. If voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Remove actuator, and check if the gear pins are in the correct cam track or binding. If OK, go to Step 3. If not OK, repair as necessary. 3. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing three times. The main temperature actuator/passenger temperature actuator on a zone system did not reach cold stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the cold to hot position, and check Pin 5 voltage it should change from 0.5 - 4 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 3.If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 3. Remove actuator, and check if gear pins are in the correct cam track or binding. If OK, go to Step 4. If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing four times. The main temperature actuator, passenger temperature actuator on a zone system did not reach hot stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from hot to cold position and check Pin 5 voltage it should change from 3.5 - 4.5 volts 0.5 - 1.5 volts. If voltage is OK, go to Step 3.If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4.If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing live times. The evaporator probe is open. 1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If not OK, if greater than 4.75 volts check for loose or corroded connector, open circuit and repair as necessary. 2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3.If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. If ground and power circuit are OK, replace Evaporator Probe. 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing six times. The evaporator probe is shorted. 1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If less than 0.1 volts, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3.If not OK, check for shorted circuit and repair as necessary. 3. If ground and power circuit are OK, replace Evaporator Probe. 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermillent LED flashing seven times. The Driver's temperature actuator on a zone system did not reach cold stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from cold to the hot position, check Pin 4 voltage it should change from 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 5343 or corroded connector, open or shorted circuit and repair as necessary. 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. 4. Check for binding doors, if door are binding repair as necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing eight times. The Driver's temperature actuator on a zone system did not reach hot stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from hot to cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary 4. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing nine times. The HVAC control module, has a internal failure. 1. Replace the HVAC control module. 2. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration and testing the A/C and RECIRC LED flashing simultaneously. Failed Cooldown test. 1. Determine if the refrigerant system is operating correctly: - Check the outlet air temperature - Feel the compressor suction plumbing, is it hot? 1. If not OK, go to Step 2.If OK, repeat the Calibration Diagnostic and Cooldown test. 2. If system does not seem to be operating correctly, perform diagnostics for poor performance: - Low refrigerant charge - No charge - Compressor not operating Verify that the test was done with the evaporator at room temperature. The test consists of starting the compressor and measuring the time it takes for the evaporator temperature to fall 7°C (20°F). If the compressor has been running, the evaporator is cold already and will not be capable of falling 7° C (20° F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the Calibration Diagnostic and Cooldown test. If refrigerant system is performing properly and the system will not pass test. Repeat the Calibration Diagnostic and Cooldown test to determine if the evaporator temperature FIN sensor has developed an open or a short circuit. If the HVAC control module still passes Calibration test, verify Cooldown test manually with a pocket thermometer. The outlet air temperature must drop at least 7° C (20° F) within two minutes. If the vehicle passes with the manual thermometer, take HVAC control to level 4 (evaporator probe temperature readout) and repeat the Cooldown test. Ensure the evaporator is at room temperature before starting test. Check if evaporator probe will drop the temperature 7° C (20° F) in two minutes. If the Evaporator Probe is found to be faulty check that the sensor is positioned in the evaporator fins properly If not, correct and repeat test. If OK, replace the evaporator probe. Once the repairs are completed, repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement Control Assembly: Service and Repair Heater-A/C Control Lamp Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. HVAC Control Lamps 2. Remove radio bezel and HVAC Control. 3. Remove rear cover from HVAC control. 4. Rotate bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from HVAC. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 5346 Control Assembly: Service and Repair Radio Bezel and HVAC Control Replacement REMOVAL 1. Remove convenience bin - cup holder. Refer to Body and Frame/Interior Trim/Drink Holder/Convenience Bin - Cup Holder Replacement. 2. Insert the trim stick (special tool #C-4755) between access cover and radio bezel, above convenience bin - cup holder. Convenience Bin Access Cover 3. Carefully pry the access cover from the instrument panel. 4. Separate the access cover from the vehicle. 5. Remove convenience bin - cup holder track. Refer to Convenience Bin - Cup Holder Track Replacement. Radio Bezel And HVAC Control 6. Remove the attaching screws holding bottom of the bezel to instrument panel. 7. Remove the attaching screws holding top of the bezel to the instrument panel. 8. Remove the bezel from the instrument panel. 9. Disconnect the wire connector from back of the rear blower switch, if equipped. 10. Disconnect the wire connector from the back of the HVAC Control. 11. Remove the bezel. INSTALLATION 1. Hold the radio bezel up and connect the wire connector into the back of the HVAC control. 2. Connect the wire connector into back of the rear blower switch, if equipped. 3. Place the radio bezel in position on the instrument panel. 4. Install screws to hold the top of radio bezel to instrument panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 5347 5. Install screws to the hold bottom of the radio bezel to the instrument panel. 6. Install the access cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 5348 Control Assembly: Service and Repair Rear Heater-A/C Switch Lamp Replacement REMOVAL 1. Remove rear heater-A/C control from trim panel. 2. On the back of control opposite from the wire connectors, locate the bulb socket lug. 3. Rotate the socket counterclockwise and pull the socket from the control. INSTALLATION For installation, reverse the above procedures. Refer to Lamps for bulb usage. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 5349 Control Assembly: Service and Repair Sticking HVAC Control Module Push Buttons Sticking HVAC Control Module Push Buttons To service HVAC control module push buttons that are sticking, spray between the buttons with Mopar MP-50. The MP-50 is a all purpose lubricant for mechanical and electrical uses. After spraying around the push buttons wipe any excess off the radio bezel and HVAC control module push buttons. Operate the buttons to ensure that they are operating freely. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................... 150 ml (5.0 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core Evaporator Core: Service and Repair Front Evaporator Core REMOVAL 1. Set parking brake. 2. Disconnect battery negative cable. A/C Service Ports 3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper module. 5. Pinch off rear heater lines if equipped. Heater Hoses 6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5355 Expansion Valve Plate 7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair". See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 9. Remove heater ducts. 10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the tunnel. HVAC Bolt Up 11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12 Disconnect the HVAC housing wiring harness. 13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle. Evaporator Core Removal 1. Place HVAC unit assembly on workbench. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5356 Distribution Housing 2. Remove distribution housing mounting screws. Blower Motor Cover 3. Remove blower motor cover. Blower Motor Grommet 4. Remove blower motor wiring grommet and feed wiring through blower housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5357 Blower Motor Screws Blower Motor 5. Remove blower motor screws. Remove blower motor from housing. Recirculation Door Cover 6. Remove recirculation door cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5358 Recirculation Door 7. Remove recirculation door. HVAC Cover 8. Remove screws around the perimeter of the upper HVAC housing. CAUTION: Do not damage the insulation barrier surrounding the evaporator. Evaporator 9. Carefully pull up on evaporator and remove from housing. 10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of the same amount (ND8 PAG) to the new Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5359 evaporator before installing. Note: For reassembly of the evaporator housing, reverse the above procedures. - Perform the HVAC control Calibration Diagnostic and Cool-down test. Refer to: "Testing and Inspection" See: Testing and Inspection INSTALLATION 1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic and Cool-down test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5360 Evaporator Core: Service and Repair Rear Evaporator Core NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Remove right quarter trim panel and D-pillar trim. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair 2. Remove fan A/C distribution duct. 3. Remove rear A/C unit. 4. Remove blower scroll. Evaporator Cover 5. Remove evaporator cover. Expansion Valve 6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5361 Evaporator Removal 7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 8. Remove and discard the 0-rings between the plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to prevent contamination. 10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil from the removed evaporator. INSTALLATION 1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch the sealing surface). Install two screws and tighten to 11 ± 3 Nm (100 ± 30 inch pounds) torque. CAUTION: Do not damage the evaporator insulation liner during installation. 3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 23 ± 3 Nm (200 ± 30 inch pounds) torque. 6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system, and perform the performance test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description and Operation Evaporator Drain Tube: Description and Operation SYSTEM OPERATION Condensate Drain Condensation from the evaporator housing is drained through the dash panel and on to the ground. This drain must be kept open to prevent water from collecting in the bottom of the housing. If the drain is blocked condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensate drainage below the vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation SYSTEM OPERATION Evaporator Probe The Evaporator probe is located on the HVAC. The probe prevents evaporator freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The probe monitors the temperature of the refrigerant after expansion. The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit and cannot be adjusted or repaired. It must be replaced if found defective. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Temperature Diagnostics The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: - Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared. To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. Display Sequence is as follows: - REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one 5 digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cooldown test is exited. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5370 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Test Evaporator Probe: Resistance Vs. Temperature Chart Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5371 Resistance Measurement Table The evaporator probe is located in the unit housing and placed in the evaporator fins. The probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature drops below freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. A malfunctioning evaporator probe may show symptoms such as: - Ice blocking the airflow, or frost exiting out of the outlets and vents - No air conditioning operation - No power to the compressor clutch during A/C selection The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) during testing. 1. Place the vehicle in a location out of direct sunlight and allow the vehicle to come to ambient temperature (the engine can remain warm). 2. With the engine OFF, lower the windows, and turn on the interior blower (with the system in Fresh Air mode). 3. Place a thermometer in one of the Instrument Panel outlets, and a second one in the intake duct (plenum area by the windshield wipers). 4. Allow the blower to run until both temperatures readings are within 2° F of one another and constant. 5. Remove the electrical connector from the evaporator probe and measure the resistance of the probe with a multimeter. 6. Consult the temperature/resistance chart and table to determine whether the resistance is within specification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5372 If the measurements fall outside the specifications, replace the evaporator probe. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Page 5373 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the glove box. Refer to Instrument Panel and Systems. Evaporator Probe Connector 2. Disconnect the evaporator probe connector. Evaporator Probe Grommet 3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing. Evaporator Probe 4. Remove evaporator probe from evaporator. INSTALLATION For installation, reverse the above procedures. Three holes are provided in evaporator for probe location. When reinstalling probe, use a different hole than original one. If a new evaporator is installed, insert the probe in the uppermost hole provided. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Testing and Inspection Expansion Valve: Testing and Inspection NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. Tests NOTE: Expansion valve tests should be performed after compressor tests. Review Safety Precautions and Warnings. The work area and vehicle temperature must be 21° C to 27° C (70° F to 85° F). To test the expansion valve: NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply facilities. CO2 is also available from companies which service and sell fire extinguishers. 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. 2. Close all doors, windows and vents to the passenger compartment. 3. Set heater A/C control to A/C, full heat, FLOOR, and high blower. 4. Start the engine and allow to idle (1000 rpm).After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. 5. If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 1655 kPa (140 to 240 psi). Suction (low pressure) gauge should read 140 kPa to 207 kPa (20 psi to 30 psig). If system cannot achieve proper pressure readings, replace the expansion valve. If pressure is correct, proceed with test. WARNING: PROTECT SKIN AND EYES FROM CONTACTING CO2 PERSONAL INJURY CAN RESULT. 6. If suction side low pressure is within specified range, freeze the expansion valve control head for 30 seconds. Use a super cold substance (liquid CO2). Do not spray R-134a or R-12 Refrigerant on the expansion valve for this test. Suction side low pressure should drop by 10 psi. If not, replace expansion valve. 7. Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 140 kPa to 240 kPa (20 psi to 30 psig). If not, replace expansion valve. 8. When expansion valve test is complete, test A/C overall performance. Remove all test equipment before returning vehicle to use. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation Expansion Valve: Service and Repair Expansion Valve Removal and Installation WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Disconnect generator field wire connector. 6. Push generator forward. 7. Remove ground wire at dash panel. A/C Refrigerant Line Plate 8. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 9. Remove the stud from the expansion valve. 10. Carefully pull the refrigerant line sealing plate assembly from expansion valve towards the front of the vehicle. Use care not to scratch the expansion valve sealing surfaces with pilot tubes. 11. Cover the openings to prevent contamination. 12. Remove two screws securing the expansion valve to the evaporator sealing plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation > Page 5379 Expansion Valve Removal 13. Carefully remove expansion valve. 14. Remove the old O-rings. INSTALLATION 1. Ensure old O-rings are removed. Install new O-rings on the refrigerant lines and evaporator sealing plate. 2. Hand-start the stud into the expansion valve and torque to 7 - 11 Nm (64 - 96 in. lbs.). 3. Carefully install the expansion valve to the sealing plate. Install the two screws and tighten 8 to 14 Nm (70 to 130 in. lbs.) torque. 4. Carefully install the refrigerant lines and sealing plate to the expansion valve. Install the nut and tighten 20 to 26 Nm (170 to 230 in. lbs.) torque. 5. Install the ground wire at dash panel. 6. Pull generator back into the proper position for bracket mounting. 7. Install generator field wire connector. 8. Install the upper generator bracket. 9. Install accessory drive belt. 10. Evacuate and recharge system. 11. After expansion valve is installed, the system is charged, and leaks have checked repeat the A/C performance check. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation > Page 5380 Expansion Valve: Service and Repair Evaporator Core and Expansion Valve Replacement NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3. Remove rear A/C unit. 4. Remove blower scroll. Evaporator Cover 5. Remove evaporator cover. Expansion Valve 6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation > Page 5381 Evaporator Removal 7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 8. Remove and discard the 0-rings between the plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to prevent contamination. 10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil from the removed evaporator. INSTALLATION 1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch the sealing surface). Install two screws and tighten to 11 ± 3 Nm (100 ± 30 inch pounds) torque. CAUTION: Do not damage the evaporator insulation liner during installation. 3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 23 ± 3 Nm (200 ± 30 inch pounds) torque. 6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system, and perform the performance test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core Heater Core: Service and Repair Front Heater Core REMOVAL 1. Drain coolant system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 2. Remove left side lower column cover. 3. Remove steering column assembly. Refer to: "Steering and Suspension : Steering : Steering Column : Service and Repair" See: Steering and Suspension/Steering/Steering Column/Service and Repair ABS Module 4. Remove ABS module, bracket and wiring. Interconnect And Bracket 5. Remove I/P to body harness interconnect and bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 5386 Lower Silencer Boot 6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood. Heater Core Plate And Tubes 8. Remove heater core cover. Insert a small amount of towels under the heater core tubes. Remove heater core plate and tubes. Depress Clips 9. Depress heater core retaining clips. Accelerator Pedal 10. Pull up on accelerator pedal and slide heater core past. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 5387 Brake Pedal 11. Depress brake pedal and remove heater core from HVAC housing. INSTALLATION For installation, reverse the above procedures. Install screws to retain heater core in housing. Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 NM (27 ± 9 in. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 5388 Heater Core: Service and Repair Rear Heater Core REMOVAL 1. Remove the lower right quarter trim panel. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair Heater Core Lines 2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4. Carefully pull the heater core and tubes up and straight out of the unit. INSTALLATION Filling Heater Core For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall performance. NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be used: - Vehicle at room temperature. - Engine is brought up to operating temperature. - Front unit is OFF, temperature slides are at full HEAT position. - Engine is at idle. - With rear blower motor ON HIGH - Discharge air temperature measured at the dual register located on the C-pillar base, is between 57° C to 62° C (135° and 145° F). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Upper Heater Hose Lower Heater Hose 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications High Pressure Safety Valve HVAC: Specifications The valve is calibrated to vent at a pressure of 3450 to 4140 kPa (500 to 600 psi) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 5395 High Pressure Safety Valve HVAC: Description and Operation SYSTEM OPERATION Compressor High-Pressure Relief Valve The High Pressure Relief Valve prevents damage to the air conditioning system if excessive pressure develops. Excessive pressure can be caused by condenser air flow blockage, refrigerant overcharge, or air and moisture in the system. The high pressure relief valve vents only a small amount of refrigerant necessary to reduce system pressure and then reseats itself. The majority of the refrigerant is conserved in the system. The valve is calibrated to vent at a pressure of 3450 to 4140 kPa (500 to 600 psi). If a valve has vented a small amount of refrigerant, it does not necessarily mean the valve is defective. The High Pressure Relief Valve is located on the compressor manifold at the discharge passage. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C Suction/Discharge Line - Service Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service NUMBER: 24-14-99 GROUP: Heating & A/C DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Suction And/Or Discharge Line Service MODELS: 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are torqued to 40 ft. lbs. (54 Nm). The root cause of A/C suction and/or discharge line cracking at or near the compressor may be related to the compressor being improperly secured to the engine. Excessive vibration may result if the compressor attaching bolts are not properly torqued. This vibration will eventually crack the aluminum tubing of the A/C lines and/or compressor mounting ears. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Recover A/C system refrigerant. Compressor Discharge Line 2. Remove discharge line mounting nut at compressor. Condenser Discharge Line 3. Remove discharge line at the top fitting on the condenser. INSTALLATION 1. For installation , reverse the above procedures. Replace all O-rings. Torque discharge line at condenser bolt to 180 in. lbs. ± 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC Control Calibration Diagnostic and Cooldown test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5402 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9. Cover the openings to prevent contamination. 10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. It may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece assembly. 13. Remove the old O-rings. INSTALLATION For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5403 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve. Suction Line At Compressor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5404 9. Remove suction line mounting nut at compressor. 10. Remove suction line mounting bracket. 11. Remove suction line. INSTALLATION For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5405 Hose/Line HVAC: Service and Repair Refrigerant Line Replacement Rear Air Conditioning Lines WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Hoist vehicle Front Lines Connected To Rear Lines 2. Remove compression fittings to the suction and liquid lines located on the right, outboard side of the underbody, rearward of the front crossmember. Rear A/C Block Connection 3. Remove (1) bolt securing A/C lines to block located on the right, outboard side of the underbody, rearward of the rear wheel and tire. Rear Heater And A/C Lines Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5406 4. Remove (3) straps securing underbody lines. 5. Separate and remove A/C lines from vehicle. INSTALLATION 1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved wax-free refrigerant oil. Then, reverse the above procedures. 2. Evacuate and recharge system. Rear Heater Lines REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Partially drain engine cooling system. Front Lines Connected To Rear Lines 2. Loosen clamp at the front end of the hose located at the right, outboard side of the underbody, rearward of the front crossmember. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. CAUTION: When removing hoses from outlet nipples, do not use excessive force. Outlet nipples may become damaged and leak engine coolant. Rear Heater Hose Quick Connects 4. Compress insert in rear heater hose quick connection and pull downward on hose. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5407 Rear Heater And A/C Lines 5. Remove (3) straps securing underbody lines. 6. Separate and remove rear heater lines from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly Housing Assembly HVAC: Service and Repair Evaporator Housing Disassembly and Assembly NOTE: In order to service the air flow control box you must first remove the evaporator core. Refer to: "Evaporator Core : Service and Repair" See: Evaporator Core/Service and Repair DISASSEMBLY 1. Place HVAC unit assembly on workbench. Distribution Housing 2. Remove distribution housing mounting screws. Blower Motor Cover 3. Remove blower motor cover. Blower Motor Grommet 4. Remove blower motor wiring grommet and feed wiring through blower housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5412 Blower Motor Screws Blower Motor 5. Remove blower motor screws. Remove blower motor from housing. Recirculation Door Cover 6. Remove recirculation door cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5413 Recirculation Door 7. Remove Recirc door. HVAC Cover 8. Remove screws around the pen meter of the upper HVAC housing. CAUTION: Do not damage the insulation barrier surrounding the evaporator. Evaporator 9. Carefully pull up on evaporator and remove from housing. 10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of the same amount (ND8 PAG) to the new evaporator before installing. Use SP 10 PAG oil for 2.5L diesel and 2.0L gasoline engine vehicles. ASSEMBLY 1. For reassembly of the evaporator housing, reverse the above procedures. 2. Perform the HVAC control Calibration Diagnostic and Cool-down test. See: Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5414 Housing Assembly HVAC: Service and Repair Heater-A/C Housing Disassembly and Assembly NOTE: In order to service the air flow control box you must first remove the evaporator core. Refer to: "Evaporator Core : Service and Repair" See: Evaporator Core/Service and Repair Distribution Housing 1. Place distribution housing on workbench. Heater Core Cover 2. Remove heater core cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5415 Heater Core Tube Plate Plate Removal 3. Remove heater core tube plate. Heater Core Tube Removal 4. Remove heater core tubes. 5. Depress heater core retaining clips at housing. When reinstalling core use screws to fasten the heater core to the housing. 6. Slide heater core out of the housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5416 Drivers Zone Actuator 7. Remove driver's zone actuator from distribution housing. Passenger Zone Actuator 8. Remove passenger zone actuator from distribution housing. Distribution Housing Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5417 Blend Air Door Drive Gear 9. Using a long thin flat blade tool, insert tool through blend-air opening on top of distribution housing. Depress clip retaining the driver's blend-air door drive gear. Pull out on gear and remove from the housing. 10. Remove mode door motor. Panel Door Gear 11. Remove Panel door actuator gear. Defrost Door Gear 12. Remove defrost door actuator gear. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5418 Cam Wheel 13. Remove cam wheel. Heat Door Gear 14. Remove heat door actuator gear. Distribution Housing 15. Remove distribution housing lower cover screws. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5419 Distribution Housing Half Screws 16. Remove distribution housing half screws. Front Cover Zone Control Doors 17. Remove distribution housing front cover. 18. Remove weather-strip at fresh-air vent. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5420 Distribution Housing Halves 19. Separate housing halves. Defrost Door 20. Pull up on separator plate and remove defrost door. Panel Door 21. Remove upper half Panel door. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5421 Floor Door 22. Remove upper half of Floor door. Blend Air Door 23. Remove upper half of the blend-air door (slide off of shaft). Separator Plate 24. Remove separator plate from distribution housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5422 Lower Blend Air Door 25. Remove lower half of the blend-air door. Lower Panel Door 26. Remove lower half of the Panel door. Lower Floor Door 27. Remove lower half of the Floor door. ASSEMBLY For reassembly of the distribution housing, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5423 NOTE: To reassemble the distribution housing actuator gears an assembly procedure of the gears and cam is necessary. ACTUATOR GEARS ALIGNMENT PROCEDURE 1. Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door actuator gear to master spline on door. 2. Install cam wheel. Align cam wheel track to FLOOR door actuator gear. 3. Align cam wheel slot with the post on the distribution housing marked "1". 4. Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master spline on PANEL door. Position actuator gear within cam wheel track. 5. Install DEFROST door actuator gear to housing. Match master spline of DEFROST door actuator to master spline on DEFROST door. Position actuator gear within cam wheel track. 6. Reinstall housing in vehicle. 7. Perform the HVAC control Calibration Diagnostic and Cool-down test. Refer to: "Testing and Inspection : Procedures" See: Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5424 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation REMOVAL WARNING: IF EQUIPPED WITH AIR CONDITIONING, THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING. 1. Set parking brake. 2. Disconnect battery negative cable. A/C Service Ports 3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Refer to: "Testing and Inspection" See: Testing and Inspection 4. Remove wiper module. Refer to Windshield Wipers and Washers. See: Wiper and Washer Systems/Service and Repair 5. Pinch off rear heater lines if equipped. Heater Hoses 6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5425 Expansion Valve Plate 7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair". See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 9. Remove heater ducts. 10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the tunnel. HVAC Bolt-up 11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12. Disconnect the HVAC housing wiring harness. 13. Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle. INSTALLATION 1. For installation of the assembly, reverse the above procedures. Install new 0-rings on plumbing inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic and Cooldown test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5426 Housing Assembly HVAC: Service and Repair Rear Heater-A/C Auxiliary Condenser Removal and Installation If vehicle is equipped with rear heater and air conditioning, it will be equipped with an auxiliary condenser. The auxiliary condenser is mounted on the primary condenser in front of the radiator. Both condenser must be removed as an assembly and then separated. WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. The condenser assembly must first be removed from vehicle. Refer to CONDENSER ASSEMBLY Replacement for service procedures. REMOVAL 1. After condenser assembly removal, place on bench for disassembly. 2. Remove (1) bolt to liquid line on auxiliary condenser. Rear Heat-A/C Auxiliary Condenser 3. Remove (4) attaching bolts and separate auxiliary from primary condenser. INSTALLATION 1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved wax-free refrigerant oil. Then, reverse the above procedures. 2. Verify seals are in place on either side and on top of the radiator. 3. Evacuate and recharge system. Refer to: "Testing and Inspection" See: Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5427 Housing Assembly HVAC: Service and Repair Rear Heater-A/C Unit Replacement and Service NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH REAR A/C, THE REFRIGERANT SYSTEM MUST BE EMPTIED BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C plumbing from rear heater A/C unit. Refer to: "Testing and Inspection" See: Testing and Inspection 2. Hoist vehicle. A/C Lines 3. Remove A/C lines at lower floor pan flange. A/C Mounting 4. Remove (3) A/C unit floor mounting nuts. 5. Lower vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5428 Quarter Trim Panel 6. Remove right quarter trim panel and D-pillar trim. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair Lower Heater Duct 7. Remove screws securing air distribution duct to the rear wheel housing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5429 Heater Core Lines 8. Pinch off heater lines at heater core hookup. Heater Hoses 9. Remove heater hoses at heater core. Trim Panel Mounting Bracket 10. Remove quarter trim panel mounting bracket. 11. Remove blower motor wiring harness connector. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5430 Upper Duct Trim 12. Remove rear upper duct trim screw. Mounting Bolts 13. Remove (2) Heater-A/C housing mounting bolts. A/C Unit Replacement 14. Pull up on upper A/C duct. Tilt A/C unit outward. 15. Lift the unit enough to clear floor pan. Remove unit from the vehicle. INSTALLATION Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5431 Filling Heater Core For installation, reverse the above procedures. Install new O-rings at refrigerant lines. Evacuate and charge the refrigerant system. Fill the heater core. Test for leaks and overall performance. NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be used: - Vehicle at room temperature. - Engine is brought up to operating temperature. - Front unit is OFF, temperature slides are at full HEAT position. - Engine is at idle. - With rear blower motor ON HIGH. - Discharge air temperature, measured at the dual register located on the C-pillar base, is between 135° and 145° F. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION . 1. Recover A/C system refrigerant. Filter-Drier Assembly 2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location. INSTALLATION 1. Before installation , replace both refrigerant line O-rings. Then reverse the above procedures. Torque filter/drier mounting bolts to 45 in. lbs. ± 10. 2. Evacuate and recharge system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................ ........................................ 0.96 kg (34 oz. or 2.13 lbs) R134a Dual Capacity ........................................................................................................................... ....................................... 1.36 kg (48 oz. or 3.00 lbs) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5439 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5440 Refrigerant: Description and Operation This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge and/or poor performance. Never add any other type of refrigerant to a system designed to use R-134a refrigerant. System failure will occur. The high pressure service port is located on the liquid line near the strut tower. The low pressure service port is located on the suction line near the compressor manifold. Refrigerant Recovery/Recycling Station (Typical) When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Manifold Gauge Set - Typical A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the oil that is specified on the under hood label. Due to the different characteristics of R-134a it requires all new service procedures. The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and low global warming impact. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair Refrigerant Filter: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION . 1. Recover A/C system refrigerant. Filter-Drier Assembly 2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location. INSTALLATION 1. Before installation , replace both refrigerant line O-rings. Then reverse the above procedures. Torque filter/drier mounting bolts to 45 in. lbs. ± 10. 2. Evacuate and recharge system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Front A/C Compressor ......................................................................................................................... ............................................................ 150 ml 5.0 oz. Dual A/C Compressor .......................................................................................................................... ............................................................ 220 ml 7.4 oz. Dual A/C Evaporator ............................................................................................................................ .............................................................. 60 ml 2.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5448 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5449 Refrigerant Oil: Service and Repair Refrigerant Oil Level Check Refrigerant Oil Capacities When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. when a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (6.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add system capacity minus the capacity of components that have not been replaced through suction port on compressor. Refer to the Refrigerant Oil Capacity Chart. 6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications Low psi control opens < 29.4 psi High psi control opens > 450 psi Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5453 A/C Pressure Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5454 Refrigerant Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION A/C Pressure Transducer A/C Pressure Transducer The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system. The transducer is located on the liquid line. The pressure transducer turns off the voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The transducer also is used to adjust condenser fan speeds and will turn off compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated unit. It must be replaced if defective. O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for the transducer. AIR CONDITIONING PRESSURE TRANSDUCER-PCM INPUT The Powertrain Control Module (PCM) monitors the A/C compressor discharge (high side) pressure through the air conditioning pressure transducer. The transducer supplies an input to the PCM. The PCM engages the A/C compressor clutch if pressure is sufficient for A/C system operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5455 Refrigerant Pressure Sensor / Switch: Testing and Inspection The work area temperature must not be below 10° C (50° F) to test the compressor clutch circuit. Before starting to test the transducer ensure that the wire connector is clean of corrosion and connected properly. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install scan tool (DRB): - Go to main menu - Select stand alone scan tool (DRB) - Select refer to the proper year diagnostics - Select climate control - Select sensor display - Select A/C high side volts For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition and will not allow the compressor to cycle. A/C Pressure Transducer Voltage Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s): 1. Connect a tachometer and manifold gauge set. 2. Set control to A/C, RECIRC, and PANEL, temperature lever on full cool and blower on high. 3. Start engine and hold at 1000 rpm with A/C clutch engaged. 4. Engine should be warmed up with doors and windows closed. 5. Insert a thermometer in the left center A/C outlet and operate the engine for five minutes. The A/C clutch may cycle depending on ambient conditions. 6. With the A/C clutch engaged, compare the discharge air temperature to the A/C Performance Temperatures table. A/C Performance Temperature Chart 7. If the discharge air temperature fails to meet the specifications in the performance temperature chart. Refer to the Refrigerant Service Procedures for further diagnosis. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5456 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect the wire connector at the pressure transducer. A/C Pressure Transducer Removal 2. Using an open end wrench, remove the transducer from the liquid line. INSTALLATION 1. Replace transducer O-ring. 2. For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations Blower Motor Relay: Component Locations Power Distribution Center -- Sheet 8w-10-2 Rear Blower Relay Rear Blower Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5462 This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5463 Blower Motor Relay: Connector Locations Power Distribution Center Front Blower Motor Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay Blower Motor Relay: Description and Operation Front Blower Motor Relay Circuit Operation Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1. The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power Distribution Center (PDC). The coil side of the relay is energized when the ignition switch is in the RUN position only. Power for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the relay Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit A22. Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl panel. Ground for the blower motor is controlled through the blower motor resistor and the blower motor switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay > Page 5466 Blower Motor Relay: Description and Operation Rear Blower Relay Circuit Operation Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear blower motor passes through the temperature sensor and one or more resistors, depending on speed selection. Two switches operate the rear blower motor by supplying ground; the front control switch and the rear control switch. The front control switch must be in the ON position for the rear control switch to operate the rear blower motor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5471 Power Distribution Center -- Sheet 8w-10-2 The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment next to the battery. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5472 Compressor Clutch Relay: Connector Locations Power Distribution Center A/C Compressor Clutch Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5473 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT The PCM operates the air conditioning clutch relay ground circuit, The radiator fan control module supplies battery power to the solenoid side of the relay. The air conditioning clutch relay will not energize unless the radiator fan control module energizes. The radiator control module energizes when the air conditioning or defrost switch is put in the ON position and the low pressure switch, combination valve, and high pressure switch close. With the engine operating, the PCM cycles the air conditioning clutch on and off when the A/C switch closes with the blower motor switch in the On position. When the PCM senses low idle speeds or wide-open-throttle through the throttle position sensor, it de-energizes the A/C clutch relay. The relay contacts open, preventing air conditioning clutch engagement. The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment next to the battery. A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation AIR CONDITIONING SWITCH SENSE-PCM INPUT When the air conditioning or defrost switch is put in the ON position and the low pressure switch, combination valve, and high pressure switch close, the PCM receives an A/C input. After receiving this input, the PCM activates the A/C compressor clutch by grounding the A/C clutch relay. The PCM also adjusts idle speed to a scheduled RPM to compensate for increased engine load. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Lamp Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel HVAC Control. Refer to Radio Bezel and HVAC Control Replacement. Rear Heater - A/C Switch Lamp Bulb 3. Rotate bulb socket counterclockwise one quarter. 4. Pull bulb socket from switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement > Page 5480 Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel and HVAC Control. Rear Heater - A/C Switch 3. Remove screw holding rear heater-A/C switch to radio bezel HVAC Control. 4. Disengage hook holding bottom of switch to radio bezel HVAC Control. 5. Remove switch from radio bezel HVAC Control. INSTALLATION For instrument, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5484 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor (Sensor Side) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5485 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Raise and support vehicle on safety stands. 3. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 4. Remove sensor from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION Rear Blower Speed Switch The rear blower speed switch controls the rear blower with the choice of low and high speeds. when the switch is on it allows the blower speed switch located on the rear headliner to control rear blower speed. This switch will override the rear headliner blower switch. For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from the A/C control module. For service procedures, refer to Instrument Panel And Gauges. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation SYSTEM OPERATION Evaporator Probe The Evaporator probe is located on the HVAC. The probe prevents evaporator freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The probe monitors the temperature of the refrigerant after expansion. The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit and cannot be adjusted or repaired. It must be replaced if found defective. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Temperature Diagnostics The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: - Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared. To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. Display Sequence is as follows: - REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one 5 digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cooldown test is exited. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5494 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Test Evaporator Probe: Resistance Vs. Temperature Chart Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5495 Resistance Measurement Table The evaporator probe is located in the unit housing and placed in the evaporator fins. The probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature drops below freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. A malfunctioning evaporator probe may show symptoms such as: - Ice blocking the airflow, or frost exiting out of the outlets and vents - No air conditioning operation - No power to the compressor clutch during A/C selection The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) during testing. 1. Place the vehicle in a location out of direct sunlight and allow the vehicle to come to ambient temperature (the engine can remain warm). 2. With the engine OFF, lower the windows, and turn on the interior blower (with the system in Fresh Air mode). 3. Place a thermometer in one of the Instrument Panel outlets, and a second one in the intake duct (plenum area by the windshield wipers). 4. Allow the blower to run until both temperatures readings are within 2° F of one another and constant. 5. Remove the electrical connector from the evaporator probe and measure the resistance of the probe with a multimeter. 6. Consult the temperature/resistance chart and table to determine whether the resistance is within specification. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5496 If the measurements fall outside the specifications, replace the evaporator probe. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Page 5497 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the glove box. Refer to Instrument Panel and Systems. Evaporator Probe Connector 2. Disconnect the evaporator probe connector. Evaporator Probe Grommet 3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing. Evaporator Probe 4. Remove evaporator probe from evaporator. INSTALLATION For installation, reverse the above procedures. Three holes are provided in evaporator for probe location. When reinstalling probe, use a different hole than original one. If a new evaporator is installed, insert the probe in the uppermost hole provided. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications Low psi control opens < 29.4 psi High psi control opens > 450 psi Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5501 A/C Pressure Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5502 Refrigerant Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION A/C Pressure Transducer A/C Pressure Transducer The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system. The transducer is located on the liquid line. The pressure transducer turns off the voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The transducer also is used to adjust condenser fan speeds and will turn off compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated unit. It must be replaced if defective. O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for the transducer. AIR CONDITIONING PRESSURE TRANSDUCER-PCM INPUT The Powertrain Control Module (PCM) monitors the A/C compressor discharge (high side) pressure through the air conditioning pressure transducer. The transducer supplies an input to the PCM. The PCM engages the A/C compressor clutch if pressure is sufficient for A/C system operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5503 Refrigerant Pressure Sensor / Switch: Testing and Inspection The work area temperature must not be below 10° C (50° F) to test the compressor clutch circuit. Before starting to test the transducer ensure that the wire connector is clean of corrosion and connected properly. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install scan tool (DRB): - Go to main menu - Select stand alone scan tool (DRB) - Select refer to the proper year diagnostics - Select climate control - Select sensor display - Select A/C high side volts For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition and will not allow the compressor to cycle. A/C Pressure Transducer Voltage Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s): 1. Connect a tachometer and manifold gauge set. 2. Set control to A/C, RECIRC, and PANEL, temperature lever on full cool and blower on high. 3. Start engine and hold at 1000 rpm with A/C clutch engaged. 4. Engine should be warmed up with doors and windows closed. 5. Insert a thermometer in the left center A/C outlet and operate the engine for five minutes. The A/C clutch may cycle depending on ambient conditions. 6. With the A/C clutch engaged, compare the discharge air temperature to the A/C Performance Temperatures table. A/C Performance Temperature Chart 7. If the discharge air temperature fails to meet the specifications in the performance temperature chart. Refer to the Refrigerant Service Procedures for further diagnosis. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5504 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect the wire connector at the pressure transducer. A/C Pressure Transducer Removal 2. Using an open end wrench, remove the transducer from the liquid line. INSTALLATION 1. Replace transducer O-ring. 2. For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation SYSTEM OPERATION Valve Service Ports The A/C service port valve cores are located within the A/C lines. The High Side (Discharge) valve service port is located on the liquid line near the right frame rail. The Low Side (Suction) valve service port is located on the suction line near the compressor. The High Side service port is a two piece port and is serviceable. The Low Side service port is not serviceable, the suction line would have to be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 5508 Service Port HVAC: Service and Repair WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. The High Side service port is serviceable, the Low Side is not serviceable. REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Unscrew the High Side service port from the liquid line. 4. Remove O-ring INSTALLATION For installation, reverse the above procedures. - Install new O-ring. - Evacuate and recharge A/C system. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5515 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to diagnose the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5520 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5521 Air Bag: Locations Driver Airbag Module Passenger Airbag Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5522 Air Bag: Diagrams Driver Airbag Squib Passenger Airbag Squib Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5523 Air Bag: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5527 Air Bag Control Module: Diagrams Airbag Control Module C1 Airbag Control Module C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5528 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs. The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or serious injury, caused by a frontal impact of the vehicle. The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5529 Air Bag Control Module: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5530 Air Bag Control Module: Service and Repair Negative Battery Cable WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Remove forward lower console from instrument panel, refer to Instrument Panel and Systems for proper procedures. Heat Duct 2. Remove screw holding lower heat duct to instrument panel support. 3. Remove heat duct from instrument panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5531 Instrument Panel Supports 4. Remove two bolts holding top of right support to instrument panel. 5. Remove two bolts holding bottom of right support to floor pan. 6. Separate right instrument panel support from vehicle. ACM Connectors 7. Disconnect two connectors from ACM. 8. Remove four bolts holding the ACM bracket assembly to floor. INSTALLATION WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET INSTALLED. CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5532 For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with the proper screws and tighten to 8.5 to 11.9 Nm (75 to 105 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5537 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5538 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5539 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5540 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5541 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5542 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5543 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5544 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5545 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5546 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5547 PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5548 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5549 POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement Clockspring Assembly / Spiral Cable: Recalls Recall 04V480000: Air Bag Clockspring Replacement Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan 1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth / Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V480000 Recall Date : OCT 05, 2004 COMPONENT: Air Bags Potential Number Of Units Affected : 955344 SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the clockspring, which is located in the hub of the steering wheel. CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a reasonable amount of time. REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an extended lifetime warranty under which it will replace the clockspring at no charge if it fails. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension Technical Service Bulletin # D17 Date: 041001 Recall - Clockspring Replacement/Warranty Extension October 2004 Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty Models 1998-2000 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP function. Note: Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with speed control and radio controls. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5562 submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5563 Customer Services Field Operations Daimler Chrysler Corporation Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. IMPORTANT: If an owner requests this recall service on a minivan that has more than 70,000 miles and an AIRBAG light that operates normally even though the owner letter clearly states that no action is necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3 of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present. 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5564 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5565 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multi-function switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5566 between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5567 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly Clockspring Assembly / Spiral Cable: Customer Interest Air Bags - Warning Lamp ON Intermittently/Constantly NUMBER: 08-011-02 GROUP: Electrical DATE: Aug. 19, 2002 SUBJECT: Air Bag Warning Indicator Lamp On OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either intermittently or constantly. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The air bag warning indicator lamp may be on intermittently or constantly. DIAGNOSIS: If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body Diagnostic Manual leads to replace the clockspring because of high resistance, perform the following additional diagnostic procedure. DISCUSSION: When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing and replacing any component. When diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool 8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test components and wiring. Only replace and/or repair the component or wiring that has been identified with the 8310 Airbag Load Tool and the DRBIII(R). NOTE: AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310 AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT. NOTE: RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE CLOCKSPRING FOR THE DRIVER'S SQUIB. PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5573 EQUIPMENT POSSIBLY REQUIRED: REPAIR PROCEDURE: 1. Determine if the Driver Squib Circuit Open DTC is active or stored. a. If DTC is active proceed to step 2. b. If DTC is stored proceed to step 3. 2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring, verify the DTC remains by turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present at this time, proceed to step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position and verify that the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to lock, continue with step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual. POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5574 TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5579 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5580 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5581 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5582 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5583 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5584 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag Clockspring Replacement Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan 1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth / Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V480000 Recall Date : OCT 05, 2004 COMPONENT: Air Bags Potential Number Of Units Affected : 955344 SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the clockspring, which is located in the hub of the steering wheel. CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a reasonable amount of time. REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an extended lifetime warranty under which it will replace the clockspring at no charge if it fails. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension Technical Service Bulletin # D17 Date: 041001 Recall - Clockspring Replacement/Warranty Extension October 2004 Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty Models 1998-2000 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP function. Note: Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with speed control and radio controls. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5594 submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5595 Customer Services Field Operations Daimler Chrysler Corporation Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. IMPORTANT: If an owner requests this recall service on a minivan that has more than 70,000 miles and an AIRBAG light that operates normally even though the owner letter clearly states that no action is necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3 of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present. 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5596 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5597 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multi-function switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5598 between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5599 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON Intermittently/Constantly NUMBER: 08-011-02 GROUP: Electrical DATE: Aug. 19, 2002 SUBJECT: Air Bag Warning Indicator Lamp On OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either intermittently or constantly. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The air bag warning indicator lamp may be on intermittently or constantly. DIAGNOSIS: If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body Diagnostic Manual leads to replace the clockspring because of high resistance, perform the following additional diagnostic procedure. DISCUSSION: When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing and replacing any component. When diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool 8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test components and wiring. Only replace and/or repair the component or wiring that has been identified with the 8310 Airbag Load Tool and the DRBIII(R). NOTE: AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310 AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT. NOTE: RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE CLOCKSPRING FOR THE DRIVER'S SQUIB. PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5604 EQUIPMENT POSSIBLY REQUIRED: REPAIR PROCEDURE: 1. Determine if the Driver Squib Circuit Open DTC is active or stored. a. If DTC is active proceed to step 2. b. If DTC is stored proceed to step 3. 2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring, verify the DTC remains by turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present at this time, proceed to step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position and verify that the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to lock, continue with step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual. POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5605 TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5610 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5615 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5616 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5617 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5618 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5619 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5620 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON Intermittently/Constantly NUMBER: 08-011-02 GROUP: Electrical DATE: Aug. 19, 2002 SUBJECT: Air Bag Warning Indicator Lamp On OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either intermittently or constantly. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The air bag warning indicator lamp may be on intermittently or constantly. DIAGNOSIS: If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body Diagnostic Manual leads to replace the clockspring because of high resistance, perform the following additional diagnostic procedure. DISCUSSION: When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing and replacing any component. When diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool 8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test components and wiring. Only replace and/or repair the component or wiring that has been identified with the 8310 Airbag Load Tool and the DRBIII(R). NOTE: AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310 AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT. NOTE: RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE CLOCKSPRING FOR THE DRIVER'S SQUIB. PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5626 EQUIPMENT POSSIBLY REQUIRED: REPAIR PROCEDURE: 1. Determine if the Driver Squib Circuit Open DTC is active or stored. a. If DTC is active proceed to step 2. b. If DTC is stored proceed to step 3. 2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring, verify the DTC remains by turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present at this time, proceed to step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position and verify that the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to lock, continue with step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual. POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5627 TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5632 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5637 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5638 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5639 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5640 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5641 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5642 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag Clockspring Replacement Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan 1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth / Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V480000 Recall Date : OCT 05, 2004 COMPONENT: Air Bags Potential Number Of Units Affected : 955344 SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the clockspring, which is located in the hub of the steering wheel. CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a reasonable amount of time. REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an extended lifetime warranty under which it will replace the clockspring at no charge if it fails. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension Technical Service Bulletin # D17 Date: 041001 Recall - Clockspring Replacement/Warranty Extension October 2004 Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty Models 1998-2000 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP function. Note: Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with speed control and radio controls. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5652 submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5653 Customer Services Field Operations Daimler Chrysler Corporation Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. IMPORTANT: If an owner requests this recall service on a minivan that has more than 70,000 miles and an AIRBAG light that operates normally even though the owner letter clearly states that no action is necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3 of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present. 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5654 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5655 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multi-function switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5656 between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5657 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5662 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5663 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5664 Clockspring Assembly / Spiral Cable: Description and Operation SYSTEM OPERATION The clockspring is snapped into a plastic mounting platform on the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the wiring harness and the driver's airbag module. This assembly consists of a flat ribbon like electrically conductive tape which winds and unwinds with the steering wheel rotation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5665 Clockspring Assembly / Spiral Cable: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5666 Clockspring Assembly / Spiral Cable: Adjustments If the rotating tape wire coil.in the clockspring is not positioned properly with the steering wheel and the front wheels, the clockspring may fail. The following procedure MUST BE USED to center the clockspring if it is not known to be properly positioned, or if the front wheels were moved from the straight ahead position. Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIR BAG COMPONENTS. 1. Adjust the steering wheel so that the tires are in a straight ahead position. 2. Remove Driver Airbag Module from steering wheel. 3. Disconnect wire connectors from back of airbag module. 4. Remove steering wheel. Clockspring Locking Tabs 5. Depress the two plastic locking pins to disengage lock mechanism. 6. With lock mechanism disengaged, rotate the clockspring rotor clockwise until the rotor stops. Do not apply excessive force. 7. From the end of travel, rotate the rotor three turns counterclockwise. The wires should end up at the top. Release locking pins to engage clockspring lock mechanism. 8. Install steering wheel and airbag. 9. Do not connect battery negative cable. Refer to Airbag System Test procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5667 Clockspring Assembly / Spiral Cable: Service and Repair Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Position steering wheel and front wheels straight ahead. 2. Release hood latch and open hood. Airbag / Horn Switch 3. Remove driver airbag from steering wheel. 4. Disconnect wire connectors from back of airbag module. 5. Disconnect the 2-way connector from remote radio control harness. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5668 6. Remove steering wheel. Airbag Clockspring 7. Remove steering column shrouds. 8. Disconnect 2-way and 5-way connectors between the clockspring and the instrument panel wiring harness. Clockspring Locking Tabs 9. Remove clockspring from housing assembly by depressing the two tabs on the clockspring. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5669 INSTALLATION For installation, reverse the above procedures. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Instrument Panel Supports The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5673 Impact Sensor: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Testing and Inspection Malfunction Lamp / Indicator: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5681 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5682 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5683 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5684 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5685 TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair Knee Diverter: Service and Repair Knee Blocker Reinforcement REMOVAL 1. Remove lower steering column cover. Knee Blocker Reinforcement 2. Remove screws holding knee blocker reinforcement to instrument panel. 3. Remove knee blocker reinforcement from vehicle. INSTALLATION 1. Place reinforcement in position. 2. Install screws to hold knee blocker reinforcement to instrument panel. 3. Install lower steering column cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5693 Air Bag Control Module: Diagrams Airbag Control Module C1 Airbag Control Module C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5694 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs. The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or serious injury, caused by a frontal impact of the vehicle. The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5695 Air Bag Control Module: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5696 Air Bag Control Module: Service and Repair Negative Battery Cable WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Remove forward lower console from instrument panel, refer to Instrument Panel and Systems for proper procedures. Heat Duct 2. Remove screw holding lower heat duct to instrument panel support. 3. Remove heat duct from instrument panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5697 Instrument Panel Supports 4. Remove two bolts holding top of right support to instrument panel. 5. Remove two bolts holding bottom of right support to floor pan. 6. Separate right instrument panel support from vehicle. ACM Connectors 7. Disconnect two connectors from ACM. 8. Remove four bolts holding the ACM bracket assembly to floor. INSTALLATION WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET INSTALLED. CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5698 For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with the proper screws and tighten to 8.5 to 11.9 Nm (75 to 105 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5704 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to diagnose the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5710 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5711 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5712 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5713 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5714 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5715 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5716 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5717 detailed instruction sheet. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5718 PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5719 POLICY: Customer Satisfaction Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5720 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5721 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5722 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5723 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5724 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5725 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5726 TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat Belt May Become Inoperative Seat Belt: Recalls Recall 02V076000: Seat Belt May Become Inoperative Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of personal injury. Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat belt assemblies. The manufacturer has reported that owner notification is expected to begin during June 2002. Owners who do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat Belt May Become Inoperative Seat Belt: All Technical Service Bulletins Recall 02V076000: Seat Belt May Become Inoperative Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of personal injury. Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat belt assemblies. The manufacturer has reported that owner notification is expected to begin during June 2002. Owners who do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement Technical Service Bulletin # 978 Date: 010801 Recall - Seat Belt Retractor Replacement August 2001 Dealer Service Instructions for: Safety Recall No. 978 -- Front Seat Belt Retractors Models 1999 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles built from December 18, 1998 through January 29, 1999 (MDH 1218XX through 0129XX) 1999 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 15, 1999 (MDH 1206XX through 0115XX) 1999 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 18, 1999 (MDH 1206XX through 0118XX) 1999 (LH) Chrysler Concorde, LHS and 300M and Dodge Intrepid NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (WJ) Jeep Grand Cherokee NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject One or both of the front seat belt retractor assemblies on about 150,000 of the above vehicles may not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 209. An improperly manufactured internal lever may not lock the seat belt retractor. This could allow increased risk of injury to a front seat occupant in certain accident conditions. Repair The front seat belt retractor assembly(s) must be replaced. Parts Information No parts will be distributed initially for this recall. Dealers should determine which Seat Belt Retractor package is required for each vehicle at the time appointments are scheduled to assure that the correct parts are available when the customer arrives. Each package contains a right and a left front seat belt retractor (except as noted) . The retractor package for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5751 ^ Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Parts Return Not required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5752 Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by firs class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer injury as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD978". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Daimlerchrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. AB Vans/Wagons IMPORTANT: Ram Vans/Wagons equipped with a sliding door require right (passenger side) front seat belt retractor assembly replacement only. 1. Open the passenger side doors. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the retractor/seat belt lower anchor bolt from the front seat riser. 5. Remove and discard the retractor assembly. 6. Install the new retractor assembly. 7. Install the retractor/seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 8. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 9. Close the turning loop cover. 10. For vehicles equipped with dual hinged side doors, repeat Steps 1-9 for the driver's side of the vehicle. AN Trucks IMPORTANT: Dakota trucks require left (driver side) front seat belt retractor assembly replacement only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5753 1. Open the driver's side door. 2. Remove the driver's door sill plate. 3. For Club Cab trucks, remove the cab back trim panel. 4. Using a small flat blade, pry the front seat belt turning loop cover open. 5. Remove the front seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 6. For Club Cab trucks, pry the rear seat belt turning loop cover open using a small flat blade. 7. For Club Cab trucks, remove the rear seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 8. Remove the quarter (B-Pillar) trim panel. 9. Remove the lower seat belt anchor bolt. 10. Remove the anchor bolt that attaches the retractor to the B-pillar. 11. Disconnect the retractor electrical connector (if equipped). 12. Remove and discard the retractor assembly. 13. Install the new retractor assembly. 14. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 15. Connect the retractor electrical connector (if equipped). 16. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 17. Install the quarter (B-pillar) trim panel. 18. For Club Cab trucks, install the rear seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 19. Install the front seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 20. Close the turning loop cover(s). 21. For Club Cab trucks, install the cab back trim panel. 22. Install the door sill plate. DN Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt from the driver's seat. 5. Remove the driver's door sill plate. 6. Remove the upper B-Pillar trim panel. 7. Remove the lower B-Pillar trim panel. 8. Disconnect the retractor electrical connector. 9. Remove the anchor bolt that attaches the retractor to the B-pillar. 10. Remove and discard the retractor assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5754 11. Remove the anti-rotation tab from the new retractor assembly and then install the new retractor assembly. 12. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Connect the retractor electrical connector. 14. Install the lower B-pillar trim panel. 15. Install the upper B-pillar trim panel. 16. Install the driver's door sill plate. 17. Install the lower seat belt anchor bolt (Figure 3). Tighten the bolt to 17 ft-lbs (23 Nm) 18. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 19. Close the turning loop cover. 20. Repeat Steps 1-19 for the passenger side of the vehicle. LH Vehicles 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the seat belt/retractor lower anchor bolt. 4. Remove the upper B-Pillar trim panel. 5. Remove the lower B-Pillar trim panel. 6. Remove and discard the retractor assembly. 7. Install the new retractor assembly. 8. Install the lower B-pillar trim panel. 9. Install the upper B-pillar trim panel. 10. Install the seat belt/retractor lower anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 11. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Close the turning loop cover. 13. Repeat Steps 1-12 for the other side of the vehicle. WJ Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt. 5. Remove the driver's door sill plate. 6. Remove the lower B-Pillar trim panel. 7. Remove and discard the retractor assembly. 8. Install the new retractor assembly. 9. Install the lower B-pillar trim panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5755 10. Install the driver's door sill plate. 11. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Close the turning loop cover. 14. Repeat Steps 1-13 for the passenger side of the vehicle. NS Minivans IMPORTANT: Town & Country minivans equipped with a taupe-colored leather interior require left (driver side) front seat belt retractor assembly replacement only. 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the upper B-Pillar trim panel. 4. Remove the seat belt floor anchor bolt. 5. Remove the lower B-Pillar trim panel. (On three door models, remove the upper bolster from the left quarter trim panel, remove the five screws across the top and three screws at the front of the trim panel and then pull the front of the quarter trim panel back far enough to access the retractor assembly.) 6. Remove the anchor bolt that attaches the retractor to the B-pillar. 7. Disconnect the retractor electrical connector, if equipped, and then remove and discard the retractor assembly. 8. Connect the retractor electrical connector, if equipped, and then install the new retractor assembly. 9. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 10. Install the lower B-pillar trim panel (or left quarter trim panel on three door models). 11. Install the seat belt floor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). Make sure that the floor anchor is properly oriented (30 outboard). 12. Install the upper B-pillar trim panel. 13. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 14. Close the turning loop cover. 15. Repeat Steps 1-14 for the other side of the vehicle if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > NHTSA01V119000 > Apr > 01 > Recall 01V119000: Seat Belt Retractor Seat Belt Retractor: Recalls Recall 01V119000: Seat Belt Retractor Vehicle Description: Certain van, wagon, pickup trucks, passenger and sport utility vehicles, fail to comply with requirements of FMVSS No. 209, "Seat Belt Assemblies." The front seat belt retractor may not comply with the requirements of the standard. If the retractor does not work properly, it will not adequately protect occupants in the event of a crash. Dealers will replace the seat belt retractor. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule for this campaign. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement Technical Service Bulletin # 978 Date: 010801 Recall - Seat Belt Retractor Replacement August 2001 Dealer Service Instructions for: Safety Recall No. 978 -- Front Seat Belt Retractors Models 1999 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles built from December 18, 1998 through January 29, 1999 (MDH 1218XX through 0129XX) 1999 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 15, 1999 (MDH 1206XX through 0115XX) 1999 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 18, 1999 (MDH 1206XX through 0118XX) 1999 (LH) Chrysler Concorde, LHS and 300M and Dodge Intrepid NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (WJ) Jeep Grand Cherokee NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject One or both of the front seat belt retractor assemblies on about 150,000 of the above vehicles may not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 209. An improperly manufactured internal lever may not lock the seat belt retractor. This could allow increased risk of injury to a front seat occupant in certain accident conditions. Repair The front seat belt retractor assembly(s) must be replaced. Parts Information No parts will be distributed initially for this recall. Dealers should determine which Seat Belt Retractor package is required for each vehicle at the time appointments are scheduled to assure that the correct parts are available when the customer arrives. Each package contains a right and a left front seat belt retractor (except as noted) . The retractor package for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5765 ^ Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Parts Return Not required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5766 Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by firs class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer injury as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD978". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Daimlerchrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. AB Vans/Wagons IMPORTANT: Ram Vans/Wagons equipped with a sliding door require right (passenger side) front seat belt retractor assembly replacement only. 1. Open the passenger side doors. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the retractor/seat belt lower anchor bolt from the front seat riser. 5. Remove and discard the retractor assembly. 6. Install the new retractor assembly. 7. Install the retractor/seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 8. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 9. Close the turning loop cover. 10. For vehicles equipped with dual hinged side doors, repeat Steps 1-9 for the driver's side of the vehicle. AN Trucks IMPORTANT: Dakota trucks require left (driver side) front seat belt retractor assembly replacement only. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5767 1. Open the driver's side door. 2. Remove the driver's door sill plate. 3. For Club Cab trucks, remove the cab back trim panel. 4. Using a small flat blade, pry the front seat belt turning loop cover open. 5. Remove the front seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 6. For Club Cab trucks, pry the rear seat belt turning loop cover open using a small flat blade. 7. For Club Cab trucks, remove the rear seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 8. Remove the quarter (B-Pillar) trim panel. 9. Remove the lower seat belt anchor bolt. 10. Remove the anchor bolt that attaches the retractor to the B-pillar. 11. Disconnect the retractor electrical connector (if equipped). 12. Remove and discard the retractor assembly. 13. Install the new retractor assembly. 14. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 15. Connect the retractor electrical connector (if equipped). 16. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 17. Install the quarter (B-pillar) trim panel. 18. For Club Cab trucks, install the rear seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 19. Install the front seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 20. Close the turning loop cover(s). 21. For Club Cab trucks, install the cab back trim panel. 22. Install the door sill plate. DN Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt from the driver's seat. 5. Remove the driver's door sill plate. 6. Remove the upper B-Pillar trim panel. 7. Remove the lower B-Pillar trim panel. 8. Disconnect the retractor electrical connector. 9. Remove the anchor bolt that attaches the retractor to the B-pillar. 10. Remove and discard the retractor assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5768 11. Remove the anti-rotation tab from the new retractor assembly and then install the new retractor assembly. 12. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Connect the retractor electrical connector. 14. Install the lower B-pillar trim panel. 15. Install the upper B-pillar trim panel. 16. Install the driver's door sill plate. 17. Install the lower seat belt anchor bolt (Figure 3). Tighten the bolt to 17 ft-lbs (23 Nm) 18. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 19. Close the turning loop cover. 20. Repeat Steps 1-19 for the passenger side of the vehicle. LH Vehicles 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the seat belt/retractor lower anchor bolt. 4. Remove the upper B-Pillar trim panel. 5. Remove the lower B-Pillar trim panel. 6. Remove and discard the retractor assembly. 7. Install the new retractor assembly. 8. Install the lower B-pillar trim panel. 9. Install the upper B-pillar trim panel. 10. Install the seat belt/retractor lower anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 11. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Close the turning loop cover. 13. Repeat Steps 1-12 for the other side of the vehicle. WJ Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt. 5. Remove the driver's door sill plate. 6. Remove the lower B-Pillar trim panel. 7. Remove and discard the retractor assembly. 8. Install the new retractor assembly. 9. Install the lower B-pillar trim panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5769 10. Install the driver's door sill plate. 11. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Close the turning loop cover. 14. Repeat Steps 1-13 for the passenger side of the vehicle. NS Minivans IMPORTANT: Town & Country minivans equipped with a taupe-colored leather interior require left (driver side) front seat belt retractor assembly replacement only. 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the upper B-Pillar trim panel. 4. Remove the seat belt floor anchor bolt. 5. Remove the lower B-Pillar trim panel. (On three door models, remove the upper bolster from the left quarter trim panel, remove the five screws across the top and three screws at the front of the trim panel and then pull the front of the quarter trim panel back far enough to access the retractor assembly.) 6. Remove the anchor bolt that attaches the retractor to the B-pillar. 7. Disconnect the retractor electrical connector, if equipped, and then remove and discard the retractor assembly. 8. Connect the retractor electrical connector, if equipped, and then install the new retractor assembly. 9. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 10. Install the lower B-pillar trim panel (or left quarter trim panel on three door models). 11. Install the seat belt floor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). Make sure that the floor anchor is properly oriented (30 outboard). 12. Install the upper B-pillar trim panel. 13. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 14. Close the turning loop cover. 15. Repeat Steps 1-14 for the other side of the vehicle if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > NHTSA01V119000 > Apr > 01 > Recall 01V119000: Seat Belt Retractor Seat Belt Retractor: All Technical Service Bulletins Recall 01V119000: Seat Belt Retractor Vehicle Description: Certain van, wagon, pickup trucks, passenger and sport utility vehicles, fail to comply with requirements of FMVSS No. 209, "Seat Belt Assemblies." The front seat belt retractor may not comply with the requirements of the standard. If the retractor does not work properly, it will not adequately protect occupants in the event of a crash. Dealers will replace the seat belt retractor. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule for this campaign. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5779 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5780 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5781 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5782 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5783 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5784 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5785 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5786 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5787 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5788 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5789 PARTS REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5790 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5791 POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Instrument Panel Supports The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5795 Impact Sensor: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation Antenna: Description and Operation SYSTEM OPERATION All models use a fixed-length stainless steel rod-type antenna mast, installed at the right front fender of the vehicle. The antenna mast is connected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis. The antenna coaxial cable has an additional disconnect, located near the right end of the instrument panel. This additional disconnect allows the instrument panel assembly to be removed and installed without removing the radio. The factory-installed Electronically Tuned Radios (ETRs) automatically compensate for radio antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the receiver or the antenna. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 5803 Antenna: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERV1CE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Antenna Test Points The ohmmeter test lead connections for each test are shown. TEST 1 Test 1 determines of the antenna mast is insulated from the base. Proceed as follows: 1. Unplug the antenna coaxial cable from the radio chassis and isolate. Remove the antenna mast. 2. Connect an ohmmeter test lead to the inside center of the antenna base. Connect the other test lead to a metallic portion on the outside of the antenna base. Check for continuity. 3. There should be no continuity. If continuity is found, replace the faulty or damaged antenna base and cable assembly. TEST 2 Test 2 checks the antenna for an open circuit as follows: 1. Unplug the antenna coaxial cable connector from the radio chassis. Remove the antenna mast. The painted mast prevents measurement directly through the mast. 2. Connect an ohmmeter test lead to the inside center of the antenna base. Connect the other test lead to the center pin of the antenna coaxial cable connector. 3. Continuity should exist the ohmmeter should only register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly. Replace the faulty base and cable if required. TEST 3 Test 3 checks the condition of the ground between the antenna base and the vehicle body as follows: 1. Connect one ohmmeter test lead to the fender on an exposed metal area paint and e-coat must be penetrated to obtain continuity). Connect the other test lead to the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less than (1) ohm. 3. If the resistance is more than (1) ohm, clean and/or tighten the antenna base to the fender mounting hardware. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Extension Cable Antenna: Service and Repair Antenna Extension Cable REMOVAL 1. Remove glove box. Antenna Cable 2. Disconnect extension cable end from antenna cable end. 3. Disconnect cable hanger clip from HVAC unit. 4. Remove radio as necessary to gain access to extension cable. 5. Disconnect extension cable from back of radio. 6. Remove extension cable from vehicle. INSTALLATION For installation reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Extension Cable > Page 5806 Antenna: Service and Repair Antenna Mast and Cable Lead REMOVAL 1. Remove glove box from instrument panel, refer to Instrument Panel and Systems for proper procedures. Antenna Cable 2. Disconnect antenna cable connector from extension cable. 3. Remove right kick trim panel. 4. Remove fender splash shield. 5. Disengage rubber grommet insulator from door hinge pillar. 6. Pull antenna cable through hinge pillar into open between door hinges. 7. Hoist and support vehicle on safety stands. 8. Remove front wheel. 9. Remove front wheelhouse splash shield. Antenna Mast 10. Remove antenna mast from antenna base. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Extension Cable > Page 5807 Antenna Cap Nut Remove/Install - Typical 11. Remove plastic cap from the cap nut. Using cap nut tool, remove cap nut holding antenna base to front fender. 12. Remove antenna base from under front fender. INSTALLATION For installation, reverse the above procedure. Torque antenna base retaining nut to 28-32 in.lbs. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Arm/Disarm Switch: Diagrams Driver Door Arm/Disarm Switch Passenger Door Arm/Disarm Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Open the front door. Front Door Ajar Switch 3. Remove the screw holding the door ajar switch to the door B-pillar. 4. Remove the door ajar switch from the B-pillar. 5. Disconnect the wire connector from the back of the ajar switch and remove the switch. INSTALLATION For installation reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 5816 Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Release the sliding door latch and allow back of the door to pop open. Sliding Door Ajar Switch 3. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar switch from quarter panel opening. 4. Disconnect the wire connector from the back of the ajar switch. 5. Remove the sliding door ajar switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. Negative Battery Cable 2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 5824 Keyless Entry Module: Adjustments The content of this article reflects the changes called out by TSB 26-09-99. PROGRAMMING RKE MODULE 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and was successful. 7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify that the RKE module will no longer accept additional Vehicle Access Code(s). 9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will require programming. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 5825 Keyless Entry Module: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws holding RKE module to instrument panel. RKE Module 4. Disconnect wire connector from RKE module. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications Keyless Entry Transmitter Battery: Specifications The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean and dry. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair Lock Cylinder Switch: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and sound pad. 3. Close the door window. 4. Disconnect the door key cylinder switch wire connector from the door harness and wiring clip from the impact beam. 5. Remove the front door outside handle from the door. Door Lock Cylinder Switch 6. Disengage the lock tab holding switch to the back of the lock cylinder. 7. Remove the switch from the door handle. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Diagrams Trunk/Liftgate Sensor/Switch (For Alarm): Diagrams Hood Ajar Switch Liftgate Arm/Disarm Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch from the vehicle. 3. Disconnect the wire connector from the liftgate ajar switch. Liftgate Ajar Switch 4. Remove the screw holding the ajar switch to the liftgate latch and remove the switch. INSTALLATION For installation, Reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page 5841 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Key Cylinder Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate trim panel. 3. Disconnect the liftgate key cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 4. Remove the liftgate outside handle. Liftgate Cylinder Lock Switch 5. Disconnect the lock tab holding the switch to the back of lock cylinder and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations Information Center Information Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Driver/Vehicle Information Display: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 Driver/Vehicle Information Display: Connector Views Connector Pin Identification Message Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 Driver/Vehicle Information Display: Electrical Diagrams Information Center Wiring Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Message Center -- Sheet 8w-46-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Message Center -- Sheet 8w-46-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 Message Center -- Sheet 8w-46-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Message Center -- Sheet 8w-46-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Message Center -- Sheet 8w-46-6 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 5872 Driver/Vehicle Information Display: Description and Operation The Overhead Console consists of a Compass/Mini-Trip Computer (CMTC), Universal Transmitter and Reading/Dome lamps. The CMTC consists of an electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC displays compass heading, trip computer with traveler messages, and exterior temperature features. For more information on CMTC features, see Instrument Panel/Compass, Outside Temperature Display, and Lighting/Dome Lamp. The Universal Transmitter replaces the hand held remote controls that open the garage door, motorized gates, or home lighting in/outside the home. This device memorizes the activator codes for up to three remote controlled devices. It triggers those devices at the push of a button, located in a unit permanently mounted in your overhead console (if equipped). The transmitter operates off the vehicle's battery and charging system; no batteries are needed. The Universal Transmitter incorporates a Rolling Code technology (random digital code signals from the remote transmitter) within the transmitter module. This is done so as an added security measure. Features of the Universal Transmitter are: ^ Can be used with most other Radio Frequency (RF) activated devices. ^ Individual channels can be trained. ^ Stores transmitter data in permanent memory- retraining is not required even if the battery dies or is disconnected. To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light up while the signal is being transmitted. NOTE: For security reasons, you are able to erase the trained frequencies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Universal Transmitter Training and Erasing Driver/Vehicle Information Display: Service and Repair Universal Transmitter Training and Erasing Universal Transmitter TRAINING 1. Turn off the engine. 2. Erase the factory test codes by pressing the two outside buttons. Release the buttons when the red light begins to flash (about 20 seconds). 3. Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. The red light on the universal transmitter will begin to flash slowly. 4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as 60 seconds), release both buttons. Your universal transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your hand-held transmitter in case you need to retrain the universal transmitter. ERASING To erase the universal transmitter codes, simply hold down the two outside buttons until the red LED begins to flash. NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 5875 Driver/Vehicle Information Display: Service and Repair Replacement Universal Transmitter REMOVAL The Universal Transmitter is serviced with the transmitter bin door, in the overhead console. Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Open transmitter bin door in rear of overhead console. 3. Gently pull towards rear of vehicle, releasing transmitter bin door. 4. Disconnect harness connector from Universal Transmitter and remove bin door from vehicle. INSTALLATION For installation, reverse the above procedures. The Universal Transmitter will need to be retrained. Refer to SERVICE PROCEDURES. Message Center REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove A-pillar trim panel. 3. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. 4. Disconnect the wire connector from back of message center 5. Remove screws holding message center to instrument panel top cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 5876 6. Remove message center from instrument panel top cover. INSTALLATION 1. Place message center in position on top cover. 2. Install screws to hold message center to instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install instrument panel top cover. 5. Install A-pillar trim. Message Center Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. Message Center Lamp Location 3. Locate the lamp in question. 4. Remove lamp and check lamp. If lamp is good test the power supply to the lamp. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Garage Door Opener Transmitter: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Garage Door Opener Transmitter: Electrical Diagrams Message Center -- Sheet 8w-46-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 Message Center -- Sheet 8w-46-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Message Center -- Sheet 8w-46-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Message Center -- Sheet 8w-46-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 Message Center -- Sheet 8w-46-6 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 5904 Garage Door Opener Transmitter: Description and Operation The Universal Transmitter replaces the hand held remote controls that open the garage door, motorized gates, or home lighting in/outside the home. This device memorizes the activator codes for up to three remote controlled devices. It triggers those devices at the push of a button, located in a unit permanently mounted in your overhead console (if equipped). The transmitter operates off the vehicle's battery and charging system; no batteries are needed. The Universal Transmitter incorporates a Rolling Code technology (random digital code signals from the remote transmitter) within the transmitter module. This is done so as an added security measure. Features of the Universal Transmitter are: ^ Can be used with most other Radio Frequency (RF) activated devices. ^ Individual channels can be trained. ^ Stores transmitter data in permanent memory- retraining is not required even if the battery dies or is disconnected. To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light up while the signal is being transmitted. NOTE: For security reasons, you are able to erase the trained frequencies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 5905 Garage Door Opener Transmitter: Testing and Inspection Before proceeding in diagnosis, check the transmitter for battery voltage and a good ground at the transmitter harness connector. - The unit may not have been trained correctly, try retraining the transmitter. - The batteries in the hand-held transmitter may be dead. - Rotate your hand-held transmitter end-over-end and train again. For best results, place the end opposite from the battery compartment against the universal transmitter while training. - The frequency of the hand-held transmitter may not be in the desired frequencies between 286MHz and 399MHz set by FCC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Universal Transmitter Training and Erasing Garage Door Opener Transmitter: Service and Repair Universal Transmitter Training and Erasing Universal Transmitter TRAINING 1. Turn off the engine. 2. Erase the factory test codes by pressing the two outside buttons. Release the buttons when the red light begins to flash (about 20 seconds). 3. Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. The red light on the universal transmitter will begin to flash slowly. 4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as 60 seconds), release both buttons. Your universal transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your hand-held transmitter in case you need to retrain the universal transmitter. ERASING To erase the universal transmitter codes, simply hold down the two outside buttons until the red LED begins to flash. NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 5908 Garage Door Opener Transmitter: Service and Repair Replacement Universal Transmitter REMOVAL The Universal Transmitter is serviced with the transmitter bin door, in the overhead console. Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Open transmitter bin door in rear of overhead console. 3. Gently pull towards rear of vehicle, releasing transmitter bin door. 4. Disconnect harness connector from Universal Transmitter and remove bin door from vehicle. INSTALLATION For installation, reverse the above procedures. The Universal Transmitter will need to be retrained. Refer to SERVICE PROCEDURES. Message Center REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove A-pillar trim panel. 3. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. 4. Disconnect the wire connector from back of message center 5. Remove screws holding message center to instrument panel top cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 5909 6. Remove message center from instrument panel top cover. INSTALLATION 1. Place message center in position on top cover. 2. Install screws to hold message center to instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install instrument panel top cover. 5. Install A-pillar trim. Message Center Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. Message Center Lamp Location 3. Locate the lamp in question. 4. Remove lamp and check lamp. If lamp is good test the power supply to the lamp. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static Amplifier: Customer Interest Instrument Panel Speaker - Intermittent Operation/Static NUMBER: 08-15-00 GROUP: Electrical DATE: Apr.21,2000 SUBJECT: Intermittent Instrument Panel Speaker Operation/Static MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND SYSTEM SALES CODES (RCE, RBN, AND RAZ). SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers. DIAGNOSIS: 1. Turn the ignition key to the RUN position. 2. Turn the radio ON. 3. Insert a known good quality CD or Tape into the sound system. 4. Increase and decrease the volume while listening for static. 5. Move the fade control fully forward, and adjust the speaker balance control from left to right while listening for static and/or intermittent operation of the speakers. 6. Increase and decrease the volume while listening for static and/or intermittent operation of the speakers. 7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the fade and speaker R/L controls are changed and the static intermittent operation does not change with volume, the static may be due to a failed speaker amplifier. Perform the following Repair Procedure to replace the speaker amplifier. 8. If static/intermittent operation is present and the static/intermittent operation changes from speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent operation may be due to a malfunctioning radio and this bulletin does not apply. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS. 1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O of the 2000 Town & Country, Caravan and Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static > Page 5919 Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: 61 - Intermittent Operation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static Amplifier: All Technical Service Bulletins Instrument Panel Speaker - Intermittent Operation/Static NUMBER: 08-15-00 GROUP: Electrical DATE: Apr.21,2000 SUBJECT: Intermittent Instrument Panel Speaker Operation/Static MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND SYSTEM SALES CODES (RCE, RBN, AND RAZ). SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers. DIAGNOSIS: 1. Turn the ignition key to the RUN position. 2. Turn the radio ON. 3. Insert a known good quality CD or Tape into the sound system. 4. Increase and decrease the volume while listening for static. 5. Move the fade control fully forward, and adjust the speaker balance control from left to right while listening for static and/or intermittent operation of the speakers. 6. Increase and decrease the volume while listening for static and/or intermittent operation of the speakers. 7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the fade and speaker R/L controls are changed and the static intermittent operation does not change with volume, the static may be due to a failed speaker amplifier. Perform the following Repair Procedure to replace the speaker amplifier. 8. If static/intermittent operation is present and the static/intermittent operation changes from speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent operation may be due to a malfunctioning radio and this bulletin does not apply. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS. 1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O of the 2000 Town & Country, Caravan and Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static > Page 5925 Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: 61 - Intermittent Operation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Page 5930 Compact Disc Player (CD): Service and Repair REMOVAL 1. Remove HVAC switch bezel, refer to Instrument Panel and Systems for proper procedure. Radio 2. Remove screws holding radio to instrument panel. Radio Connectors 3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from back of radio. 7. Remove radio from vehicle. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Radio/Stereo Noise Filter: Customer Interest Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5940 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5941 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5942 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5943 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Radio/Stereo Noise Filter: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5949 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5950 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5951 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5952 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation Remote Switch: Description and Operation SYSTEM OPERATION Remote Radio Switches Remote Radio Switch Operational View A remote radio control switch option is available on LXI models sold in North America with the AM/FM/ cassette/5-band graphic equalizer with CD changer control feature (RBN sales code), or the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 5956 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switches 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. REMOTE RADIO SWITCH TEST Switch position = Resistance Volume Up = 7320 Ohms Volume Down = 1210 Ohms Seek Up = 4530 Ohms Seek Down = 2050 Ohms Pre-set station advance = 10 Ohms NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right"/Left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity If OK, refer to the proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK, repair the open circuit as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 5957 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from the remote radio switch(s). 8. Remove three screws securing steering wheel rear cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side of switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be careful to index them correctly before pressing them into place. Tighten the airbag module mounting screws to 10.2 Nm (90 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static Speaker: Customer Interest Instrument Panel Speaker - Intermittent Operation/Static NUMBER: 08-15-00 GROUP: Electrical DATE: Apr.21,2000 SUBJECT: Intermittent Instrument Panel Speaker Operation/Static MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND SYSTEM SALES CODES (RCE, RBN, AND RAZ). SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers. DIAGNOSIS: 1. Turn the ignition key to the RUN position. 2. Turn the radio ON. 3. Insert a known good quality CD or Tape into the sound system. 4. Increase and decrease the volume while listening for static. 5. Move the fade control fully forward, and adjust the speaker balance control from left to right while listening for static and/or intermittent operation of the speakers. 6. Increase and decrease the volume while listening for static and/or intermittent operation of the speakers. 7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the fade and speaker R/L controls are changed and the static intermittent operation does not change with volume, the static may be due to a failed speaker amplifier. Perform the following Repair Procedure to replace the speaker amplifier. 8. If static/intermittent operation is present and the static/intermittent operation changes from speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent operation may be due to a malfunctioning radio and this bulletin does not apply. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS. 1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O of the 2000 Town & Country, Caravan and Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static > Page 5966 Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: 61 - Intermittent Operation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static Speaker: All Technical Service Bulletins Instrument Panel Speaker - Intermittent Operation/Static NUMBER: 08-15-00 GROUP: Electrical DATE: Apr.21,2000 SUBJECT: Intermittent Instrument Panel Speaker Operation/Static MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND SYSTEM SALES CODES (RCE, RBN, AND RAZ). SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers. DIAGNOSIS: 1. Turn the ignition key to the RUN position. 2. Turn the radio ON. 3. Insert a known good quality CD or Tape into the sound system. 4. Increase and decrease the volume while listening for static. 5. Move the fade control fully forward, and adjust the speaker balance control from left to right while listening for static and/or intermittent operation of the speakers. 6. Increase and decrease the volume while listening for static and/or intermittent operation of the speakers. 7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the fade and speaker R/L controls are changed and the static intermittent operation does not change with volume, the static may be due to a failed speaker amplifier. Perform the following Repair Procedure to replace the speaker amplifier. 8. If static/intermittent operation is present and the static/intermittent operation changes from speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent operation may be due to a malfunctioning radio and this bulletin does not apply. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS. 1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O of the 2000 Town & Country, Caravan and Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-15-00 > Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static > Page 5972 Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: 61 - Intermittent Operation Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 5973 Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 5974 Speaker: Diagrams Junction Block Name Brand Speaker Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 5975 Speaker: Description and Operation SYSTEM OPERATION Choke - Infinity Speakers If the audio system is cutting in and out at higher volumes, check for continuity across the choke connector. If no continuity replace the choke assembly The choke is located on the junction block/body control module. Name Brand Speaker Relay Relay is located in the junction block. To test relay refer to the Audio Diagnostic Test Procedures or use a known good relay. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker Speaker: Service and Repair D-Pillar Speaker REMOVAL 1. Remove D-pillar trim panel as necessary to gain access to door speaker. 2. Disconnect wire connector from speaker. D-Pillar Speaker 3. Remove by sliding speaker out of bracket by pushing on magnet. The capacitor is wrapped with foam tape. 4. Remove speaker. INSTALLATION For installation reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 5978 Speaker: Service and Repair Front Door Speaker REMOVAL 1. Remove front door trim panel as necessary to gain access to door speaker. Front Door Speaker 2. Remove screws holding speaker to bracket. 3. Remove speaker from bracket. 4. Disconnect wire connector from speaker. 5. Remove speaker. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 5979 Speaker: Service and Repair Instrument Panel Speaker REMOVAL 1. Remove instrument panel top cover. Left Instrument Panel Speaker Right Instrument Panel Speaker 2. Remove screws holding speaker to instrument panel and remove speaker. 3. Remove anti rocking finger screw. 4. Disconnect wire connector from speaker. 5. Remove speaker. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 5980 Speaker: Service and Repair Quarter Panel Speaker REMOVAL 1. Remove quarter trim bolster from quarter trim panel. Quarter Panel Speaker 2. Remove screws holding speaker to inner quarter panel. 3. Separate speaker from quarter panel. 4. Disconnect wire connector from speaker. 5. Remove speaker. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair REMOVAL 1. Remove HVAC switch bezel, refer to Instrument Panel and Systems for proper procedure. Radio 2. Remove screws holding radio to instrument panel. Radio Connectors 3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from back of radio. 7. Remove radio from vehicle. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 5988 Keyless Entry Module: Adjustments The content of this article reflects the changes called out by TSB 26-09-99. PROGRAMMING RKE MODULE 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and was successful. 7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify that the RKE module will no longer accept additional Vehicle Access Code(s). 9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will require programming. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 5989 Keyless Entry Module: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws holding RKE module to instrument panel. RKE Module 4. Disconnect wire connector from RKE module. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Arm/Disarm Switch: Diagrams Driver Door Arm/Disarm Switch Passenger Door Arm/Disarm Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Open the front door. Front Door Ajar Switch 3. Remove the screw holding the door ajar switch to the door B-pillar. 4. Remove the door ajar switch from the B-pillar. 5. Disconnect the wire connector from the back of the ajar switch and remove the switch. INSTALLATION For installation reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 5998 Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Release the sliding door latch and allow back of the door to pop open. Sliding Door Ajar Switch 3. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar switch from quarter panel opening. 4. Disconnect the wire connector from the back of the ajar switch. 5. Remove the sliding door ajar switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. Negative Battery Cable 2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair Lock Cylinder Switch: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and sound pad. 3. Close the door window. 4. Disconnect the door key cylinder switch wire connector from the door harness and wiring clip from the impact beam. 5. Remove the front door outside handle from the door. Door Lock Cylinder Switch 6. Disengage the lock tab holding switch to the back of the lock cylinder. 7. Remove the switch from the door handle. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation Remote Switch: Description and Operation SYSTEM OPERATION Remote Radio Switches Remote Radio Switch Operational View A remote radio control switch option is available on LXI models sold in North America with the AM/FM/ cassette/5-band graphic equalizer with CD changer control feature (RBN sales code), or the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 6008 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switches 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. REMOTE RADIO SWITCH TEST Switch position = Resistance Volume Up = 7320 Ohms Volume Down = 1210 Ohms Seek Up = 4530 Ohms Seek Down = 2050 Ohms Pre-set station advance = 10 Ohms NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right"/Left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity If OK, refer to the proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK, repair the open circuit as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 6009 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from the remote radio switch(s). 8. Remove three screws securing steering wheel rear cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side of switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be careful to index them correctly before pressing them into place. Tighten the airbag module mounting screws to 10.2 Nm (90 in. lbs.). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Diagrams Trunk/Liftgate Sensor/Switch (For Alarm): Diagrams Hood Ajar Switch Liftgate Arm/Disarm Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch from the vehicle. 3. Disconnect the wire connector from the liftgate ajar switch. Liftgate Ajar Switch 4. Remove the screw holding the ajar switch to the liftgate latch and remove the switch. INSTALLATION For installation, Reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page 6015 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Key Cylinder Switch REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate trim panel. 3. Disconnect the liftgate key cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 4. Remove the liftgate outside handle. Liftgate Cylinder Lock Switch 5. Disconnect the lock tab holding the switch to the back of lock cylinder and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Compass/Mini-Trip Computer Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions Trip Computer: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Trip Computer: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Compass/Mini-Trip Computer Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 Compass/Mini-Trip Computer Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6086 Trip Computer: Description and Operation COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer is located in the overhead console. The CMTC consists of a electronic control module with a vacuum fluorescent display (VFD) and function switches. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: Average Fuel Economy (AVG ECO) - Distance To Empty (DTE) - Instantaneous Fuel Economy (ECO) - Elapsed Time (ET) - Trip Odometer (ODO). Pushing the STEP button when the ignition is ON will cause the CMTC to change mode of operation. The information needed for the traveler functions is received over the CCD bus from the Body Control Module. If the Compass/Mini-Trip Computer has been replaced, it may be necessary to reset the calibration. SYSTEM OPERATION Compass/Mini-Trip Computer Self Diagnostic Test The Compass/Mini-Trip Computer (CMTC) is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a DRB lll scan tool and the proper Body Diagnostic Procedures or by the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP button. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check, the CMTC will display: PASS - FAIL - CCD If any segment of the CMTC fails to light, replace the module. If FAIL is displayed, replace the module. If CCD is displayed, check the CCD and Body Control Module (BCM) for proper operation, refer to the appropriate diagnostic test procedures. If the CCD and the BCM are OK, replace the CMTC module. For additional diagnostic information on the CMTC and for identifying CMTC problems, refer to the proper Body Diagnostic Procedures. Compass Mini-Trip Computer (CMTC) Compass Mini-Trip Computer (CMTC) Switches and Display Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6087 The CMTC module in the overhead console has three buttons used to select various functions. The CMTC selector buttons will not operate until the ignition is in the RUN position. When the ignition switch is first turned to the RUN position the CMTC display: Blanks momentarily - All segments of the VFD will light for one second - Blanks momentarily - Returns to the last mode setting selected before the ignition was last switched OFF. Thermometer Engine temperature can increase the displayed temperature. The CMTC is designed to dampen temperature readings when the vehicle is moving at a rate slower than 18 miles per hour. The outside temperature is measured from a sensor mounted in the front of the vehicle. If the temperature is more than 55 °C (131 °F) or the temperature sending line is shorted to ground, the temperature display should read SC. If the temperature is less than -40 °C (-40 °F), or the sending line is an open circuit, the display should read OC. The CMTC will not allow the temperature reading to increase when the vehicle is not moving. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and Inspection > Testing Trip Computer: Testing and Inspection Testing The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a scan tool and the proper Body Control Module Testing and Inspection Procedures or by using the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check the CMTC will display. PASS - FAIL - CCD If any segment of the CMTC fails to light replace the module. If FAIL is displayed replace the module. If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper operation. If the CCD bus and the BCM are OK, replace the CMTC module. Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and Inspection > Testing > Page 6090 Trip Computer: Testing and Inspection Traveler Messages Traveler data is obtained from the Body Control Module (BCM) on the CCD bus wires. The CMTC will not display information for any of the screens for which it did not receive the bus messages. The label corresponding to the missing information will be lit. If no traveler data is displayed, check the CCD bus communications and the BCM. If the brightness level is improper check the CCD bus. One general method for checking the CCD bus communications between CMTC and the BCM is refer to the following procedure. 1. STEP the CMTC to the Elapsed Time (ET). 2. Press and release the reset button to reset the module. 3. If the elapsed time clock does not reset, or fails to update, check the CCD bus wires and the BCM. The DRB lll is recommended for checking the CCD bus and the BCM. 4. Perform the CMTC self diagnosis before replacing the CMTC. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Compass/Mini-Trip Computer (CMTC) Lamp Bulbs Trip Computer: Service and Repair Compass/Mini-Trip Computer (CMTC) Lamp Bulbs REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body and Frame/Interior Trim/Overhead Console Replacement. CMTC Lamp Bulbs 3. Rotate bulb socket counterclockwise one quarter turn. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Compass/Mini-Trip Computer (CMTC) Lamp Bulbs > Page 6093 Trip Computer: Service and Repair Compass/Mini-Trip Computer (CMTC) Module REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body and Frame/Interior Trim/Overhead Console Replacement. Compass Mini-Trip Computer 3. Remove the six screws holding CMTC module to overhead console. 4. Remove CMTC module from console. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions NUMBER: 26-12-99G GROUP: Miscellaneous DATE: December, 1999 THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revisions to the wiring schematics Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6100 8W-44-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6101 8W-44-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6102 8W-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6103 8W-50-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6104 8W-50-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6105 8W-50-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6106 8W-80-15 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6107 8W-90-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6108 8W-90-11 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6109 Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6110 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6111 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6112 Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set NO: 18-25-98 GROUP: Vehicle Performance DATE: Aug. 14, 1998 SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code MODELS: 1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE. DISCUSSION: During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous "EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the ignition to the ON position and determine if each PRNDL indicator in the instrument cluster becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not necessary to replace the BCM. NOTE: CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL FAILURE IN THE PRNDL SYSTEM. POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6113 Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 6116 Junction Block, Body Control Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Body Control Module: Connector Views Body Control Module C1 (A) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Body Control Module C2 (B) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Body Control Module Interconnect Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Body Control Module: Electrical Diagrams BCM Block Diagram Wiring Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Body Control Module -- Sheet 8w-45-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Body Control Module -- Sheet 8w-45-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Body Control Module -- Sheet 8w-45-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Body Control Module -- Sheet 8w-45-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 Body Control Module -- Sheet 8w-45-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Body Control Module -- Sheet 8w-45-7 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 Body Control Module -- Sheet 8w-45-8 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 Body Control Module -- Sheet 8w-45-9 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Page 6150 Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 Body Control Module: Description and Operation Part 1 of 3 INTRODUCTION Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. This information will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not come on at all - warning lamp stays on BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: automatic door locks - battery protection - CCD radio - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 6153 - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar, ignition, RKE actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as described above. Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and glove box closed). Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened, The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 6154 Body Control Module: Description and Operation Part 2 of 3 COMPASS/MINI-TRIP COMPUTER The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. See the service procedure. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Compass Magnetic Variance Zones Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the following zone map provided. The number shown for your area is the variance number for your area. 1. Set the compass/mini-trip console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation, NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS. MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb check is performed. This consists of activating all CCD controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 6155 as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Programming an RKE Transmitter Customer Programming Method NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED. 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds. While still holding the unlock button, press the panic button, then release both buttons. The BCM will acknowledge that it has grounded the RKE module program enable wire by sounding a single chime tone. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition off. DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON, place the transmission in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in Programming Mode" does not appear, exit and select "Program RKE" again. 4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle (up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode sooner, press "Back Page". RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 6156 Body Control Module: Description and Operation Part 3 of 3 VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE COMMUNICATIONS. Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system Will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 6157 System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all door are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Test - NOTE: System self-test can be entered only with the DRB. NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH A VEHICLE THEFT SECURITY SYSTEM. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. WIPER SYSTEM Front The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned OFF the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. DRB III (R) ERROR MESSAGES Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User- Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 6158 DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition WARNINGS Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light GLOSSARY OF ACRONYMS ACM Airbag Control Module AECM Airbag Electronic Control Module (type of ACM) ASDM Airbag System Diagnostic Module (type of ACM) BCM body control module CAB controller antilock brake CCD Chrysler Collision Detection (vehicle communications bus) CMTC Compass/Mini-Trip Computer (module) DLC data link connector (previously called "engine diagnostic connector") DR driver HVAC heater, ventilation, air condition MET metric MIC mechanical instrument cluster MUX multiplexed ODO odometer PASS passenger PCM powertrain control module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 3 > Page 6159 PDC powertrain distribution center PTC positive temperature coefficient RKE remote keyless entry TCM transmission control module VF vacuum fluorescent display VTSS vehicle theft security system Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures AM/FM Switch Inoperative SYMPTOM * AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Joystick Inoperative SYMPTOM * BALANCE JOYSTICK INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Cassette Error SYMPTOM CASSETTE ERROR POSSIBLE CAUSES - Cassette Error / Replace radio CD Eject Switch Inoperative SYMPTOM * CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Error SYMPTOM CD ERROR POSSIBLE CAUSES - Defective radio Equalizer Inoperative SYMPTOM * EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - Radio/CD cable loose/disconnected - DIN cable data bus (CAV 1) open - DIN cable data bus (CAV 3) open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6162 - DIN cable terminals shorted - DIN signal wires (CAVS 2, 4, and 5) open - DIN fused B(+) circuit open - DIN fused ignition switch output circuit open - DIN ground circuit open - DIN metal connectors open - Radio defective - Radio input control defective FF/RW Switch Inoperative SYMPTOM * FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM * HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12V output circuit defective, open - Radio ground circuit defective, open - Power relay output circuit defective, open - Radio 12V output circuit shorted to ground - Radio choke defective - Speaker power relay defective, open - Speaker power relay defective, open - Junction block defective, open circuit - Defective radio - Radio choke output circuit defective, open - Radio output circuits defective No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Door or quarter speaker (+) circuit defective, open - Door or quarter speaker (-) circuit defective, open - Door or quarter speaker (+) circuit open - Door or quarter speaker (-) circuit open - Instrument panel or pillar speaker (+) circuit open - Instrument panel or pillar speaker (-) circuit open - Door or quarter speaker defective - Speaker defective, no response Pause/Play Switch Inoperative SYMPTOM * PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6163 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector defective - Antenna connections defective - Hood ground defective - Ground circuit defective, open - Radio connectors not properly connected - Ignition / alternator system noise - Radio defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Ground circuit open - Instrument panel - pillar speaker defective - Radio choke output circuit open - Speaker (+) and (-) circuits shorted together - Inoperative speaker defective PWR Switch Inoperative SYMPTOM * PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Radio Error SYMPTOM RADIO ERROR POSSIBLE CAUSES - Defective radio Remote Controls Inoperative SYMPTOM * REMOTE CONTROLS INOPERATIVE POSSIBLE CAUSES - No response, CCD bus failure - Radio control harness defective, open - Radio control MUX circuit shorted - Remote control switch defective - MUX control clockspring defective - Radio control ground circuit to BCM open - Radio control MUX circuit open - Radio MUX control circuit defective - Body Control Module defective Scan Switch Inoperative SYMPTOM * SCAN SWITCH INOPERATIVE TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6164 This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM * SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Set Switch Inoperative SYMPTOM * SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Left door speaker shorted - Left front instrument panel speaker shorted - Right door speaker shorted - Right front instrument panel speaker shorted - Right front (-) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (+) circuit shorted to ground - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left door speaker defective, shorted - Left front instrument panel speaker defective, shorted - Left quarter speaker shorted - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear speaker shorted - Left front (+) and (-) circuits shorted together - Left front (+) circuit shorted to ground - Left front (-) circuit shorted to ground - Radio output circuits defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Right rear quarter speaker shorted Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6165 - Left rear (+) and (-) circuits shorted together - Left rear (+) circuit shorted to ground - Left rear (-) circuit shorted to ground - Left rear quarter speaker shorted - Left rear speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Right rear pillar speaker shorted - Radio output circuits defective Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right channel speaker shorted - Right instrument panel speaker defective, shorted - Right front (+) circuit shorted to ground - Right front (+) and (-) circuits shorted together - Right front (-) circuit shorted to ground - Right pillar speaker shorted - Right quarter speaker shorted - Right rear (+) and (-) circuits shorted together - Right rear (+) circuit shorted to ground - Right rear (-) circuit shorted to ground - Radio output circuits defective Tape Eject Switch Inoperative SYMPTOM * TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Tune Switch Inoperative SYMPTOM * TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM * VOL/TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM * 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6166 Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - BCM fails chime test Chime Inoperative With Driver Seat Belt Unfastened SYMPTOM * CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Ground circuit to left seat belt switch connector open - Left seat belt switch open - BCM not responding to belt switch - Body Control Module seat belt switch sense open - Seat belt switch sense circuit open Chime Inoperative With Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition Switch - key in switch shorted - BCM - no chime response - head/park lamps ON - BCM - key in sense shorted default - BCM - no response to park lamp switch - Chime inoperative with exterior lamps ON Chime Inoperative With Key In Ignition & Driver Door Open SYMPTOM * CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Ignition switch ground circuit open - Key in ignition switch sense circuit open - Ignition switch - key in switch open - BCM - no chime to key in ignition - BCM not responding to key in switch Chime Inoperative With L or R Turn Signal On For 1 Mile SYMPTOM * CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE POSSIBLE CAUSES - Junction block - Left turn signal open - Junction block - Right turn signal open - BCM - no response to turn signal - BCM fails speed test - Chime - speedometer problem - Chime inoperative - turn signal on for 1 mile Chime Inoperative With Low Oil Pressure SYMPTOM Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6167 * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - BCM - No response to oil pressure - BCM fails chime test Chime Inoperative With the Dome Lamps On SYMPTOM * CHIME INOPERATIVE WITH THE DOME LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM failed - door open & key out default - BCM - key in switch sense shorted default Chime Sounds With Driver Door Open & Key Out SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT POSSIBLE CAUSES - Key in ignition switch sense circuit shorted - Ignition switch - key in switch shorted - BCM - key in switch sense shorted default - BCM not responding to key out Chime Sounds With Driver Seat Belt Fastened SYMPTOM * CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch sense circuit shorted to ground - Left seat belt switch shorted - BCM - no response to seat belt fastened - BCM seat belt switch input shorted to ground Auto Headlamps Will Not Turn Off SYMPTOM * AUTO HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - No response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Auto headlamp signal circuit shorted to ground - Electrochromic mirror defective - sensor stuck ON (default) - BCM defective - auto headlamp sensor stuck ON Auto Headlamps Will Not Turn On SYMPTOM * AUTO HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - NO response (BCM) - CCD bus failure - NO response (PCM) - CCD bus failure - Auto headlamp signal circuit open - Electrochromic mirror defective (default) - BCM defective - auto headlamp sensor Fog Lamps Will Not Turn Off SYMPTOM * FOG LAMPS WILL NOT TURN OFF Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6168 POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp switched ground circuit shorted to ground - Headlamp switch defective - foglamp switched ground Fog Lamps Will Not Turn On SYMPTOM * FOG LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Fog lamp bulbs open - Fog lamp relay control circuit open - Fog lamp relay output circuit open - Fog lamp relay defective, open - Multifunction dimmer switch defective (open) default - Fog lamp switched ground circuit open - BCM defective - Headlamp relay control - Multifunction switch defective (fog lamp relay control) default - Headlamp relay control circuit (foglamps) open Headlamps Will Not Turn Off SYMPTOM * HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch sense circuit shorted to ground - Headlamp relay control circuit shorted to ground - Low beam relay control circuit shorted to ground - Low beam relay control circuit (QUAD) shorted to ground - Low beam headlamp relay (QUAD) defective, shorted - Low beam headlamp relay defective (shorted) by default - PDC defective (low beam headlamp relay connector shorted) - Headlamp switch defective - switch sense - BCM defective (headlamp switch sense function) by default - BCM defective (low beam relay control shorted) by default Headlamps Will Not Turn On SYMPTOM * HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Both low beam fuses open - Fused low beam output circuit open (both lamps inoperative) - Fused low beam output circuit open (one lamp inoperative) - Headlamp defective (by default) - Headlamp fuse open - Headlamp switch sense circuit open - Headlamps defective (by default) - Multifunction switch defective (default) - Headlamp relay control circuit open - Low beam relay control circuit (Chrysler) open - Low beam relay control circuit open - Low beam headlamp relay defective (by default) - Low beam relay defective - relay control function - PDC defective - B(+) circuit at low beam fuse terminal - Power Distribution Center defective (low beam relay CAV A) - Power Distribution Center defective (low beam relay CAV B) - Headlamp switch defective (by default) - BCM defective - headlamp switch sense function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6169 - BCM defective - headlamp switch sense stuck open - BCM defective - low beam relay control open Park Lamps Will Not Turn Off SYMPTOM * PARK LAMPS WILL NOT TURN OFF POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Park lamp relay control circuit shorted to ground - Park lamp relay output circuit shorted to voltage - Park lamp switch sense circuit shorted to ground - Park lamp relay defective - control shorted (by default) - Headlamp switch defective - shorted - BCM defective - park lamp switch sense closed (by default) Park Lamps Will Not Turn On SYMPTOM * PARK LAMPS WILL NOT TURN ON POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Headlamp switch ground circuit open - Fused park lamp output circuit open - Park lamp bulb defective (by default) - Park lamp fuse in PDC open - Both park lamp fuses open - Park lamp fuse open - Park lamp relay control circuit open - Park lamp relay output circuit open - Park lamp switch sense circuit open - Park lamp relay defective (control function) - PDC defective - other B(+) cavity - PDC defective - park lamp relay connector, fused B(+) - Headlamp switch defective - park lamps (by default) - BCM defective - park lamp switch sense stuck open - BCM defective - park lamp switch sense function - BCM defective - parklamp control function (by default) ABS Warning Lamp SYMPTOM * ABS WARNING LAMP POSSIBLE CAUSES - BCM connector observable defect - CAB connector observable defect - Fused ignition switch output circuit open - ABS warning lamp defective - ABS warning lamp driver circuit open - ABS warning lamp driver circuit shorted to ground - ABS warning lamp flashing - BCM defective - CAB defective Airbag Warning Lamp SYMPTOM * AIRBAG WARNING LAMP POSSIBLE CAUSES - Airbag warning lamp failure All Warning Lamps Out SYMPTOM * ALL WARNING LAMPS OUT Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6170 POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Information Center defective Engine Temperature Warning Lamp SYMPTOM * ENGINE TEMPERATURE WARNING LAMP POSSIBLE CAUSES - Engine temperature lamp staying on - Temperature lamp not working - Engine temperature lamp/bulb defective - Fused ignition switch output circuit open - Defective BCM - Engine temperature warning lamp driver circuit open - Temperature warning lamp driver circuit shorted to ground - Information Center defective - Body Control Module defect - Defective Information Center High Beam Indicator Lamp SYMPTOM * HIGH BEAM INDICATOR LAMP POSSIBLE CAUSES - Headlamps inoperative - Fused right highbeam output circuit open - Ground circuit open - High beam indicator bulb defective - Defective Information Center Low Oil Pressure Warning Lamp SYMPTOM * LOW OIL PRESSURE WARNING LAMP POSSIBLE CAUSES - Oil pressure low - Oil warning lamp/bulb defective - Oil level low - Defective oil pressure switch - Oil pressure switch sense circuit shorted to ground - Oil pressure switch sense circuit open - Oil pressure switch defective - BCM defective - Defective Information Center Red Brake Warning Lamp SYMPTOM * RED BRAKE WARNING LAMP POSSIBLE CAUSES - Park brake pedal problem - Vehicle equipped antilock brakes - Brake fluid level low - Red brake warn lamp/bulb defective - Ground circuit open - Brake fluid level switch defective - Defective ignition switch - Defective park brake switch - Red brake warning lamp circuit open - Red brake warning lamp circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6171 - Information Center faulty - Ignition switch defective - Red brake warning lamp driver circuit open - Red brake warning lamp driver circuit faulty Service Engine Soon Lamp SYMPTOM * SERVICE ENGINE SOON LAMP POSSIBLE CAUSES - DTC's are present - Bulb & socket defective - Service Engine Soon indicator lamp driver circuit open - Service Engine Soon indicator lamp circuit shorted to ground - Defective Information Center circuit board - Powertrain Control Module defective Turn Signal Indicator Lamp SYMPTOM * TURN SIGNAL INDICATOR LAMP POSSIBLE CAUSES - Turn signal lamps inoperative - Ground circuit open - Left turn signal circuit open - Right turn signal circuit open - Turn signal bulbs defective - Junction Block defective - BCM defective - Information Center defective Vehicle Theft Alarm Indicator SYMPTOM * VEHICLE THEFT ALARM INDICATOR POSSIBLE CAUSES - Vehicle theft alarm indicator defective All Gauges Inoperative SYMPTOM * ALL GAUGES NOT OPERATING POSSIBLE CAUSES - BCM instrument cluster circuit output defective - Instrument Cluster PC board defective - DRB shows ignition unlock closed - No response - CCD bus instrument cluster - Body computer odometer failure - RAM test failure - ROM test failure Cluster Illumination SYMPTOM * CLUSTER ILLUMINATION POSSIBLE CAUSES - No response - CCD bus instrument cluster - Headlamp switch ground circuit defective - Inoperative lamp defective - Headlamp switch defective - Junction block defective - Dimmer switch signal circuit open - Dimmer switch signal circuit shorted to ground Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6172 - Instrument panel lamps driver circuit shorted to ground - Panel lamps driver circuit open - Park lamps not lighting - Instrument Cluster circuit board defective - BCM dimmer switch signal circuit output faulty - BCM defective - BCM defective by default - Body computer odometer failure - BCM dimmer switch signal circuit defective - Illumination panel fuse OK - Inoperative lamp ground circuit - RAM test failure - ROM test failure Cluster Warning Lamps Odometer and PRNDL Display SYMPTOM * CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY POSSIBLE CAUSES - Any one lamp/bulb defective - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Body computer odometer failure DTC - No response - CCD bus instrument cluster - Washer fluid level switch defective - BCM washer fluid switch sense circuit input defective - All segments fail to light - Faulty odometer and PRNDL lamp - Generator lamp failure - Instrument cluster printed circuit board defective Gauges Not Returning to Zero With Key Off SYMPTOM * GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF POSSIBLE CAUSES - Fused B(+) circuit open - No response - CCD bus instrument cluster - Instrument Cluster PC board defective - Body computer odometer failure - RAM test failure - ROM test failure One Gauge Not Operating Properly SYMPTOM * ONE GAUGE OPERATING IMPROPERLY POSSIBLE CAUSES - DRB reads active on the bus - DRB reads no vehicle speed sense signal code - IOD fuse is loose in junction block - Speedometer calibration out - Any one lamp/bulb defective - DRB reading not matching RPM - Washer fluid level switch sense circuit open - Washer fluid level switch sense ground circuit open - Washer fluid level switch sense circuit shorted - Washer fluid level switch defective - Gauge pack defective - Speedometer/Odometer gauge pack defective - Tachometer calibration out - Cooling system condition faulty - DRB reads coolant temperature sensor code Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6173 - DRB reads engine temperature accurately - BCM instrument cluster circuit output defective - Body Control Module defective - Gauge pack defective - Instrument Cluster printed circuit board defective - DRB shows ignition unlock closed - BCM washer fluid level switch sense circuit input defective - All segments fail to light - BCM temperature gauge input defective - Faulty odometer and PRNDL lamp - Generator lamp failure - PCM defective - Pinion factor failure Trip and Rest Button(S) SYMPTOM * TRIP AND RESET BUTTON(S) POSSIBLE CAUSES - Trip & reset button(s) defective Courtesy Lamps Inoperative W/Dome Lamp Switch SYMPTOM * COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH POSSIBLE CAUSES - Courtesy lamp switch sense circuit open - Headlamp switch defective - courtesy lamp function open - BCM defective - courtesy lamp switch sense (by default) - BCM defective - dome lamp switch function Courtesy Lamps Inoperative With Any Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH ANY DOOR POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay control circuit open - Switched courtesy lamp relay control circuit open - Junction block defective - lamp relay fused B(+) (CAV 87) open - Courtesy lamp relay defective - coil open - Junction block defective - lamp relay fused B(+) (CAV 30) open - Junction block defective - lamp relay fused B(+) (CAV 86) Open - Headlamp switch defective - open - BCM defective - lamp relay control function (by default) - BCM defective - driver door ajar switch status Courtesy Lamps Inoperative With Driver Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR POSSIBLE CAUSES - Driver door ajar switch defective, open - Driver door ajar switch sense circuit open - Left front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Left Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR POSSIBLE CAUSES - Left sliding door ajar switch sense circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6174 - Left sliding door ajar ground circuit open - Left sliding door ajar switch defective, open - BCM defective Courtesy Lamps Inoperative With Liftgate SYMPTOM * COURTESY LAMPS INOPERATIVE WITH LIFTGATE POSSIBLE CAUSES - Liftgate ground circuit open - Liftgate ajar switch open - ajar switch disconnected - Liftgate ajar switch sense circuit open - BCM defective, open Courtesy Lamps Inoperative With Passenger Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR POSSIBLE CAUSES - Passenger door ajar switch defective, open - Passenger door ajar switch sense circuit open - Right front door switch ground strap corroded/damaged - Body Control Module inoperative, open Courtesy Lamps Inoperative With Right Sliding Door SYMPTOM * COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR POSSIBLE CAUSES - Right sliding door ajar switch defective, open - Right sliding door ajar switch sense circuit open - Right sliding door ajar ground circuit open - BCM defective, open Courtesy Lamps On at All Times SYMPTOM * COURTESY LAMPS ON AT ALL TIME POSSIBLE CAUSES - No response (BCM) - CCD bus failure - Courtesy lamp relay output circuit shorted to B(+) - Courtesy lamp relay control circuit shorted to ground - Switched courtesy lamp relay control circuit shorted to ground - Courtesy lamp relay defective - coil shorted - Headlamp switch shorted - BCM defective - relay control shorted (by default) Illuminated Entry Inoperative With Driver Door Key Cylinder SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER POSSIBLE CAUSES - Driver door key switch unlock position stuck - Driver door key cylinder switch defective - Driver door key switch sticking Illuminated Entry Inoperative With RKE Transmitter SYMPTOM * ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6175 - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective unlock switch - RKE module default replacement - RKE module defective CMTC Avg MPH/Fuel Economy Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR WRONG POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative CMTC Elapsed Time Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective BCM / Indicator lights CMTC Fails to Respond to Instrument Cluster Dimming SYMPTOM * COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Trip Odometer Inoperative or Wrong SYMPTOM * COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE/WRONG. POSSIBLE CAUSES - No PCM communications - TPS inoperative - VSS signal inoperative Compass/Mini-Trip Computer Displaying OC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING OC POSSIBLE CAUSES - Open sensor ground circuit - Ambient Temperature Sensor defective - Open Ambient Temperature Sensor signal circuit - Defective Compass/Mini-Trip Module - sensor ground circuit. Compass/Mini-Trip Computer Displaying SC SYMPTOM * COMPASS/MINI-TRIP COMPUTER DISPLAYING SC POSSIBLE CAUSES - Defective Ambient Temperature Sensor - Ambient Temperature Sensor signal circuit shorted to ground - Compass/Mini-Trip Module default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6176 Compass/Mini-Trip Computer Segments Fail to Light SYMPTOM * COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - segments fail to light Compass/Mini-Trip Computer Shows Failed SYMPTOM * COMPASS/MINI-TRIP COMPUTER SHOWS FAILED POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - shows failed Compass/Mini-Trip Computer Switch Inoperative SYMPTOM * COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER DIMMING. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Incorrect Ambient Temperature Readings SYMPTOM * INCORRECT AMBIENT TEMPERATURE READINGS POSSIBLE CAUSES - Open sensor ground - defective CMTM - Sensor ground circuit partial short to ground - Defective Ambient Temperature Sensor/Road test - Ambient Temperature Sensor signal circuit partial short - Ambient Temperature Sensor signal circuit shorted - Defective Compass/Mini-Trip Module - Defective Compass/Mini-Trip Module sensor ground circuit Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH POSSIBLE CAUSES - Junction block defective - Door unlock relay output circuit open - Door unlock relay output circuit resistance low Additional All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door unlock relay control inoperative at BCM - Door unlock relay defective - Door unlock relay coil resistance out of tolerance - Door unlock relay output circuit shorted to ground Additional All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6177 POSSIBLE CAUSES - Passenger door switch MUX shorted to battery - Door lock switch resistance high in unlock position - Driver door switch MUX circuit shorted to battery - Liftgate switch MUX shorted to battery - BCM door lock relay control circuit inoperative - Liftgate switch MUX at BCM defective - Door lock relay control ground circuit open - Door lock relay defective - Fuse # 26 defective - Fused B(+) circuit open - Fused B(+) circuit shorted to ground - Ground circuit open at door lock relay connector Additional All Doors Fail to Lock and Unlock From One Switch SYMPTOM ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH POSSIBLE CAUSES - Door key cylinder switch connector circuit ground circuit open - Door key cylinder switch defective - Liftgate key cylinder switch defective - Liftgate switch MUX shorted to battery - Door switch MUX circuit to BCM open - Driver door switch MUX circuit open at BCM connector - Liftgate switch MUX circuit open at BCM connector - Liftgate switch MUX circuit to BCM open - Passenger door switch MUX circuit open at BCM connector - Passenger door switch MUX circuit to BCM open - Door lock switch connector ground circuit open - Door lock switch defective - Door lock switch MUX circuit open - Door locks inoperative from key cylinder switch - Door switch MUX circuit shorted to battery Additional All Doors Failing to Lock From Any Switch SYMPTOM ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH POSSIBLE CAUSES - Fused B(+) circuit voltage too low at junction block - Door lock relay control circuit from BCM fails - Key - in ignition switch circuit to BCM defective - Door lock relay does not operate - Door lock relay coil resistance out of tolerance - Door lock relay output shorted to ground - Ignition switch defective - Key - in ignition switch sense circuit shorted to ground Additional Driver Door (w/RKE) Failing to Unlock From Any SW SYMPTOM ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Driver door unlock relay coil resistance out of tolerance - Driver door unlock relay defective - Driver door unlock relay output circuit shorted to ground - Voltage too low at junction block fused B(+) circuit Additional One Door Fails to Lock and Unlock From Any Switch SYMPTOM ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6178 POSSIBLE CAUSES - RKE equipped door lock fails to lock & unlock - Door lock motor defective - Driver unlock relay ground open in junction block - Door lock relay output circuit open - Door unlock relay output circuit open - Driver door unlock relay open All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors (Exc Driver w/RKE) Fail to Unlock SYMPTOM * ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK POSSIBLE CAUSES - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - Defective door lock switch - Defective door unlock switch - RKE module default replacement - RKE module defective All Doors Fail to Lock and Unlock From Any Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Defective door lock switch - Defective unlock switch All Doors Fail to Lock and Unlock From One Switch SYMPTOM * ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Lock From Any Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6179 - Defective unlock switch All Doors Failing to Lock From One Switch SYMPTOM * ALL DOORS FAILING TO LOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch All Doors Failing to Unlock From One Switch SYMPTOM * ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Automatic Door Locks Do Not Lock Over 15 MPH SYMPTOM * AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH POSSIBLE CAUSES - Link to body communication bus inoperative - TPS malfunction causes door lock problem - VSS malfunction causes door lock problem - Auto door lock not enabled Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - BCM defective - BCM sends wrong key - in ignition status - BCM a connector terminals damaged - Ignition switch open - Key - in ignition switch ground circuit open - Key - in ignition switch sense circuit open Driver Door (w/RKE) Failing to Unlock From Any Switch SYMPTOM * DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH TEST NOTE This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch One Door Fails to Lock and Unlock From Any Switch SYMPTOM * ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH TEST NOTE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6180 This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH. POSSIBLE CAUSES - Defective door lock switch - Defective unlock switch Remote Keyless Entry Problem SYMPTOM * RKE PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative - RKE circuit at BCM defective - RKE ground circuit open - RKE fused B(+) circuit open - RKE interface circuit open - RKE interface circuit shorted to ground - RKE program enable circuit open - RKE program enable circuit shorted to ground - RKE module default replacement - RKE module defective Front Wiper Operating Constantly W/Switch In Off Position SYMPTOM * FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION POSSIBLE CAUSES - Front wiper ON/OFF relay control circuit shorted to ground - Defective wiper ON relay/substitute relay - Defective multifunction switch/voltage - High/Low wiper relay HI speed output circuit shorted to voltage - High/Low wiper relay LO speed output circuit shorted to voltage - Defective BCM - 100 ohms default Front Wipers Not Parking In Off Position SYMPTOM * FRONT WIPERS NOT PARKING IN OFF POSITION TEST NOTE This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN POSSIBLE CAUSES - Wiper park switch toggle closed/open - Open wiper park switch sense circuit - Defective BCM - wiper park switch - Defective wiper motor/wiper park switch Front Wipers Not Working at All SYMPTOM * FRONT WIPERS NOT WORKING AT ALL POSSIBLE CAUSES - Open wiper on relay control circuit - BCM/wiper relay - Defective wiper ON relay - BCM/ground - Front wiper switch MUX circuit shorted to ground - Open front wiper switch MUX circuit between switch and BCM - Defective High/Low wiper relay - relay connector - Defective multifunction switch/front wiper switch - High/Low wiper relay HI speed output circuit shorted to ground - High/Low wiper relay LO speed output circuit shorted to ground - Open ground circuit/lights - Open High/Low relay LO speed output circuit between High/Low relay and wiper motor - Open fused ignition switch output circuit/multifunction switch - Defective Power Distribution Center - relay connector Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6181 - Defective Power Distribution Center - front wiper relay - Defective Power Distribution Center - wiper ON relay - Defective Power Distribution Center - wiper relay - Defective Power Distribution Center - H/L relay - Defective Power Distribution Center - B(+) circuit. - Defective wiper motor/harness - Defective BCM/wiper relay - Defective BCM/front wiper MUX - Defective BCM/sensors - Defective wiper motor ground circuit. Front Wipers Not Working In High Speed Mode SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE POSSIBLE CAUSES - Open HI/LO wiper relay control circuit - Defective HI/LO wiper RELAY - Wiper switch - Open wiper HI/LO relay HI speed output circuit - Defective multi - FUNCT switch/ ground circuit - Defective power DIST CNTR-H/L WPR RLY - Defective wiper Motor/HI speed output circuit - Open ground circuit/Multi - Function switch Front Wipers Not Working In Intermittent Mode SYMPTOM * FRONT WIPERS NOT WORKING IN INTERMITTENT MODE POSSIBLE CAUSES - Defective multifunction switch/positions - Defective BCM/wiper positions - Defective multifunction switch/Default Front Wipers Not Working In Low Speed Mode SYMPTOM * FRONT WIPERS NOT WORKING IN LOW SPEED MODE POSSIBLE CAUSES - High/Low wiper relay control circuit shorted to ground - Defective High/Low wiper relay - fused ignition switch - Open High/Low wiper relay - LO speed output circuit - Defective wiper motor/LO speed output circuit Rear Washer Motor Inoperative SYMPTOM * REAR WASHER MOTOR INOPERATIVE POSSIBLE CAUSES - Open rear washer motor control circuit - Defective rear washer motor/jumper - Open fused ignition switch output circuit/voltage - Defective HVAC Control Module / 3.8 volts - Defective BCM - washer motor operate Rear Wiper Not Parking In the Off Position SYMPTOM * REAR WIPER NOT PARKING IN THE OFF POSITION POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective HVAC Control Module/switch indicator lights - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6182 - Defective BCM/washer motor run - Defective BCM/cycle on default - Defective BCM/rear wiper switch voltage - Defective rear wiper motor/test light Rear Wiper Not Working at All SYMPTOM * REAR WIPER NOT WORKING AT ALL POSSIBLE CAUSES - Open rear wiper motor control circuit - Open rear wiper switch MUX circuit - Open ground circuit/rear wiper motor - Open fused ignition switch output circuit/fuse # 6 - Open fused ignition switch output circuit/fuse # 8 - Shorted fused ignition switch output circuit/fuse # 6 - Defective rear wiper motor/motor control - Defective HVAC Control Module/default - Defective HVAC Control Module/rear wiper switch MUX - Defective BCM/rear wiper switch MUX - Defective BCM/rear wiper motor - Defective HVAC Control Module/21-Way connector Rear Wiper Not Working In the Intermittent Mode SYMPTOM * REAR WIPER NOT WORKING IN THE INTERMITTENT MODE POSSIBLE CAUSES - Defective rear wiper motor/intermittent switch - Defective HVAC Control Module/indicator light - Defective HVAC Control Module/rear wiper switch - Defective BCM/test light default Rear Wiper/Wash Working Continuously SYMPTOM * REAR WIPER/WASH WORKING CONTINUOUSLY POSSIBLE CAUSES - Rear wiper motor control circuit shorted to battery - Defective wiper motor/wiper motor connector - Defective BCM/rear wiper motor - default - Defective BCM/washer motor run - Defective BCM/rear wiper switch voltage Wiper/Wash Function Not Working Properly SYMPTOM * WIPER/WASH FUNCTION NOT WORKING PROPERLY POSSIBLE CAUSES - Defective washer motor/washer pump control - Operate wipers - Open washer pump control circuit - Defective multifunction switch/washer pump control - Open fused ignition switch output circuit - Defective junction block/BCM - Defective junction block/block connector - Defective BCM/junction block - Defective BCM/stalk switch - Fused ignition switch output circuit shorted to ground - Open washer pump control circuit/multifunction switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6183 Body Control Module: Component Tests and General Diagnostics Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6184 Body Control Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A. DRB Scan Tool Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6185 Body Control Module: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) Body Control Module - Location 4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Refer to Instrument Panel and Systems, Body Control Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6186 Body Control Module: Tools and Equipment DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Roll door glass up. 2. Remove the watershield. (Refer to Front Door Panel.) 3. Through access hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector from door harness, if equipped. 4. Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. 5. Disengage clip holding door latch linkage to door latch. 6. Remove latch linkage from latch. 7. Disengage clip holding door lock linkage to door latch. 8. Remove lock linkage from latch. Fig. 19 9. Remove nuts holding outside door handle to door outer panel (Fig. 19). 10. Remove outside door handle from vehicle. INSTALLATION If outside door handle replacement is necessary, transfer lock cylinder from the original handle to the new one. 1. Place outside door handle in position on vehicle. 2. Install nuts attaching outside door handle to door outer panel (Fig. 19) . 3. Insert lock linkage into door latch. 4. Engage ,clip to hold door lock linkage to latch. 5. Insert latch linkage into door latch. 6. Engage clip to hold door latch linkage to latch. 7. Install push-in fasteners to hold VTSS switch harness to inner door reinforcement bar, if equipped. 8. Connect VTSS switch connector into door harness, if equipped. 9. Verify door latch operation. 10. Install sound shield and door trim panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN AREA WHERE THEY CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE. REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel and sound pad. 3. Tape the window in its existing position to remove its weight from the regulator system. 4. Cut and remove the tie wrap at the window motor. Its no longer required. 5. Disconnect window motor wire connector from door harness. 6. Remove screws and nuts holding window motor to the inner panel. 7. Remove the motor from the door inner panel, let it hang from the cables. 8. With the cables still attached to the failed motor, Install the replacement motor to the door inner panel. Tighten down the screws and nuts to 3.4 to 4.5 Nm (30 to 40 in. lbs.) of torque. 9. Separate the failed motor from regulator by: - Removing the drum cover plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 6197 Power Window Motor Removal - Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously. CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the cables unwind. INSTALLATION 1. Install the cable guide and drum into the replacement motor. CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor shaft by a slight rotation,then, the glass should be lowered a small amount approximately 1 to 2 inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance of a second person. 2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the wiring harness to the window motor connector. 4. Remove the tape holding the window in place and test window operation. 5. Re-assemble remaining parts in reverse order as above. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair Sliding Door Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove sliding door trim panel. 2. Remove sliding door stop bumper. 3. Peel watershield away from adhesive around perimeter of inner door panel as necessary to access outside release handle fasteners. 4. Remove latch/lock control cover. 5. Disengage clip holding outside door handle linkage to door handle. 6. Remove linkage from outside door handle. 7. Remove linkage from latch/lock control. Fig. 31 8. Remove nuts holding outside door handle to outer door panel (Fig. 31). 9. Remove outside door handle from vehicle. INSTALLATION 1. Position outside door handle on vehicle. 2. Install nuts attaching outside door handle to outer door panel. 3. Insert linkage into outside door handle. 4. Engage clip to hold linkage to outside door handle. 5. Engage rigging-cam to latch/lock control mechanism. 6. Move clip on latch/lock control to bottom of slot and engage linkage to latch/lock control. 7. Verify sliding door operation. Adjust as necessary. 8. Install latch/lock cover. 9. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 10. Install sliding door stop bumper. 11. Install sliding door trim panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. Negative Battery Cable 2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams Liftgate Lock Motor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Liftgate Ajar Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications Cross-Member: Specifications To Body Attaching Bolts ...................................................................................................................... ................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12 ............................................................................................................................................ 108 Nm (80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14 .......................................................................................................................................... 166 Nm (123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts ............................................................................................................................................... 165 Nm (123 ft. lbs.) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 Console: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement Console: Service and Repair Console Replacement REMOVAL Lower Console 1. Remove screws holding lower console to floor bracket and instrument panel. 2. Slide console rearward from around instrument panel supports. 3. Remove lower console. INSTALLATION 1. Place lower console in position. 2. Slide console forward around instrument panel supports. 3. Install screws to hold lower console to floor bracket and instrument panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 6243 Console: Service and Repair Convenience Bin Lamp Unused Convenience Bin Lamp Socket Location If the lamp is not used refer to the above image. REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Pull out and remove the convenience bin cup holder. Refer to Body and Frame/Interior Trim/Drink Holder/Convenience Bin - Cup Holder removal. 3. Insert the trim stick (special tool #C-4755) between access cover and radio bezel, above convenience bin - cup holder. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 6244 Convenience Bin Access Cover 4. Carefully pry the access cover from the instrument panel. 5. Separate the access cover from the vehicle. 6. Using needle-nose pliers, carefully squeeze the vertical metal legs of the lamp hood. 7. Lift the lamp hood upward from the cup holder tray. Convenience Bin Lamp Bulb 8. Carefully pull the lamp and wiring rearward from the instrument panel. 9. Pull the lamp hood from the lamp socket. 10. Pull bulb from socket. INSTALLATION For installation, for reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 6245 Console: Service and Repair Convenience Bin Track REMOVAL 1. Remove the convenience bin - cup holder. Refer to Convenience Bin - Cup Holder Replacement. Convenience Bin Access Cover 2. Remove the screw access cover from the bottom of the radio bezel. 3. Remove the center bezel. Convenience Bin Track 4. Remove the convenience bin track attaching screws and pull the convenience bin track rearward to disengage the rear guide studs from instrument panel. 5. Disengage the clip holding convenience bin lamp to track 6. Remove the convenience bin track. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 6246 Console: Service and Repair Demagnetizing Procedure A magnetic field can adversely affect the compass. Magnetic interference can magnetize the roof panel. Magnetizing can be caused by placing a permanent magnet in contact with the roof panel. Example: - Magnetic Base Antenna - Magnetic screwdriver - Audio speakers - Refrigerator magnets. - Pizza Signs - Bubble gum flasher lights Removing magnetic interfering objects will usually restore normal compass operation. If the compass display remains blank while the CAL label is illuminated, then the roof panel requires demagnetizing. To demagnetize use Special Tool 6029 for demagnetizing the roof panel. The demagnetizing procedure will demagnetize the roof and mounting screws in the overhead console. It is important that you follow the instructions below exactly. The mounting screws and the mounting brackets around the compass area are steel, and therefore aid in the demagnetizing of the roof panel. 1. Be sure the ignition switch is in the OFF position before you begin the demagnetize procedure. 2. Plug the demagnetizing tool into a standard 110/115 volt AC outlet, keeping the demagnetizing tool at least 12 inches away from the compass area when plugging it in. 3. Slowly approach and contact the console mounting screw with the plastic coated tip of the tool for at least two seconds. 4. With the demagnetizing tool still energized, slowly back it away from the screw until the tip is at least 12 inches from the screw head. 5. Repeat the last step with all the console mounting screws. 6. After you have pulled at least 12 inches from the last screw, remove the demagnetizing tool from inside vehicle and disconnect it from the electrical outlet. 7. Place an 8 1/2 X 11 inch piece of paper lengthwise on the roof of vehicle directly above compass. The purpose of the paper is to protect the roof panel from scratches and define the area to be demagnetized. 8. Plug in the demagnetizing tool, keeping it at least two feet away from the compass unit. 9. Slowly approach the center of the roof panel at the windshield with the demagnetizing tool plugged in. 10. Contact the roof panel with the tip of the tool. Using slow sweeping motions of 1/2 inch between sweeps. Move the tool approximately four inches either side of the center line and at least 11 inches back from the windshield. 11. With the demagnetizing tool still energized, slowly back away from the roof panel until the tip is at least two feet from the roof before unplugging the tool. 12. Recalibrate compass, refer to the compass calibration procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 6247 Console: Service and Repair Overhead Console Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Overhead Console 2. Open the transmitter bin door. 3. Remove screw holding the overhead console to the headliner. With the screw removed the console is retained by one engagement tab located inside the eyeglass storage bin. 4. Open the eyeglass bin door. 5. Press the retaining tab which is located directly above the door latch. 6. Lower rear of console away from headliner. 7. Pull console rearward to disengage clips holding front of console to roof armature and lower console. 8. Disconnect wire connectors from back of CMTC and reading lamps. Ensure the connectors lock tabs are fully depressed before disconnecting. 9. Remove overhead console. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Page 6248 Degausser 6029 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6254 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to diagnose the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair REMOVAL Convenience Bin - Cup Holder 1. Pull the convenience bin open. 2. Push lock tab at rear center downward. 3. Pull the convenience bin - cup holder from track in instrument panel. 4. Remove convenience bin - cup holder. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair Glove Compartment Lock: Service and Repair REMOVAL Glove Box Lamp Striker 1. Open glove box door. 2. Disengage clip holding checkstraps to glove box door. 3. Remove screws holding lock striker to instrument panel. 4. Remove glove box lock striker. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > Customer Interest: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs Quarter Panel Trim Panel: Customer Interest Right Side Sliding Door Trim Panel - Rubs Quarter Panel NUMBER: 23-33-99 GROUP: Body DATE: Aug. 13, 1999 SUBJECT: Right Side Sliding Door Trim Panel Rubs Quarter Panel OVERVIEW: This bulletin involves replacing the two top center sliding door trim panel clips. MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES VEHICLES BUILT PRIOR TO JULY 15, 1999 (MDH 0715XX). SYMPTOM/CONDITION: The right side sliding door trim panel contacts the quarter panel when the door is opened because the two top center sliding door trim panel clips do not retain the trim panel to the door tight enough. DIAGNOSIS: Open the right sliding door, if there is contact between the sliding door trim panel and the quarter panel, perform the Repair Procedure. PARTS REQUIRED: 2 06505292AA Clip, Trim Panel AR (1) 04796237 Cleaner/Wax EQUIPMENT REQUIRED: Fiber Stick REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Using a fiber stick remove the right side sliding door upper frame molding. 2. Remove the three screws attaching the trim panel to the door. 3. Disengage the clips around the perimeter of the trim panel that hold the trim panel to the door with a fiber stick. 4. Remove the top two center clips from the trim panel and the top two center clip grommets from the door. 5. Install the revised clips, p/n 06505292AA to the trim panel. 6. Place the trim panel in position on the vehicle. 7. Align the locating pins on the backside of the trim panel to the mating holes in the inner door panel. 8. Engage the clips to hold the trim panel to the door. 9. Install the three screws that attach the trim panel to the door. 10. Install the upper frame molding. 11. If the paint is scuffed use Mopar Cleaner/Wax, p/n 04796237, to polish the paint. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > Customer Interest: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs Quarter Panel > Page 6270 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-23-94 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs Quarter Panel Trim Panel: All Technical Service Bulletins Right Side Sliding Door Trim Panel - Rubs Quarter Panel NUMBER: 23-33-99 GROUP: Body DATE: Aug. 13, 1999 SUBJECT: Right Side Sliding Door Trim Panel Rubs Quarter Panel OVERVIEW: This bulletin involves replacing the two top center sliding door trim panel clips. MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES VEHICLES BUILT PRIOR TO JULY 15, 1999 (MDH 0715XX). SYMPTOM/CONDITION: The right side sliding door trim panel contacts the quarter panel when the door is opened because the two top center sliding door trim panel clips do not retain the trim panel to the door tight enough. DIAGNOSIS: Open the right sliding door, if there is contact between the sliding door trim panel and the quarter panel, perform the Repair Procedure. PARTS REQUIRED: 2 06505292AA Clip, Trim Panel AR (1) 04796237 Cleaner/Wax EQUIPMENT REQUIRED: Fiber Stick REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Using a fiber stick remove the right side sliding door upper frame molding. 2. Remove the three screws attaching the trim panel to the door. 3. Disengage the clips around the perimeter of the trim panel that hold the trim panel to the door with a fiber stick. 4. Remove the top two center clips from the trim panel and the top two center clip grommets from the door. 5. Install the revised clips, p/n 06505292AA to the trim panel. 6. Place the trim panel in position on the vehicle. 7. Align the locating pins on the backside of the trim panel to the mating holes in the inner door panel. 8. Engage the clips to hold the trim panel to the door. 9. Install the three screws that attach the trim panel to the door. 10. Install the upper frame molding. 11. If the paint is scuffed use Mopar Cleaner/Wax, p/n 04796237, to polish the paint. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs Quarter Panel > Page 6276 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-23-94 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trim Panel: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension Trim Panel: Service and Repair A-Pillar Lower Extension A-PILLAR LOWER EXTENSION TRIM REMOVAL 1. Remove instrument panel side cover. 2. Remove screw holding A-pillar extension to door hinge pillar. 3. Separate A-pillar extension trim from vehicle A-pillar. INSTALLATION 1. Place A-pillar extension trim in position on vehicle. 2. Install screw to hold A-pillar extension to door hinge pillar. 3. Install instrument panel side cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6289 Trim Panel: Service and Repair A-Pillar Trim A-PILLAR TRIM PANEL REMOVAL 1. Disengage hidden clips holding A-pillar trim panel to A-pillar. 2. Separate A-pillar trim from vehicle. INSTALLATION 1. Position foot on A-pillar trim panel into instrument panel top cover channel. 2. Position A-pillar trim in vehicle. 3. Align locator pins. 4. Engage hidden clips. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6290 Trim Panel: Service and Repair Cowl Trim COWL TRIM REMOVAL 1. Remove door sill plate. 2. Disengage hidden clips holding cowl trim to cowl panel. 3. Separate cowl trim from vehicle. INSTALLATION 1. Place cowl trim sill plate in position on vehicle. 2. Engage hidden clips to hold cowl trim to cowl panel. 3. Install door sill plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6291 Trim Panel: Service and Repair Front Door Sill Plate FRONT DOOR SILL PLATE REMOVAL 1. Using trim stick, disengage hidden clips holding door sill plate from door sill. 2. Separate sill plate from vehicle. INSTALLATION 1. Place sill plate in position on vehicle. 2. Align locating pins on backside of trim plate to mating holes in door sill. 3. Engage hidden clips to hold door sill plate to door sill. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6292 Trim Panel: Service and Repair A-Pillar Lower Extension A-PILLAR LOWER EXTENSION TRIM REMOVAL 1. Remove instrument panel side cover. 2. Remove screw holding A-pillar extension to door hinge pillar. 3. Separate A-pillar extension trim from vehicle A-pillar. INSTALLATION 1. Place A-pillar extension trim in position on vehicle. 2. Install screw to hold A-pillar extension to door hinge pillar. 3. Install instrument panel side cover. A-Pillar Trim A-PILLAR TRIM PANEL REMOVAL 1. Disengage hidden clips holding A-pillar trim panel to A-pillar. 2. Separate A-pillar trim from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6293 INSTALLATION 1. Position foot on A-pillar trim panel into instrument panel top cover channel. 2. Position A-pillar trim in vehicle. 3. Align locator pins. 4. Engage hidden clips. Cowl Trim COWL TRIM REMOVAL 1. Remove door sill plate. 2. Disengage hidden clips holding cowl trim to cowl panel. 3. Separate cowl trim from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6294 INSTALLATION 1. Place cowl trim sill plate in position on vehicle. 2. Engage hidden clips to hold cowl trim to cowl panel. 3. Install door sill plate. Front Door Sill Plate FRONT DOOR SILL PLATE REMOVAL 1. Using trim stick, disengage hidden clips holding door sill plate from door sill. 2. Separate sill plate from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6295 INSTALLATION 1. Place sill plate in position on vehicle. 2. Align locating pins on backside of trim plate to mating holes in door sill. 3. Engage hidden clips to hold door sill plate to door sill. Front Door Trim Panel REMOVAL 1. Using a trim stick (C-4755), pry courtesy lamp from door trim. 2. Disconnect wire connector from courtesy lamp. 3. If equipped, remove screws attaching door assist handle to inner door panel. 4. If equipped, remove screw attaching door pull cup to inner door panel. 5. If equipped, remove screws attaching trim panel to door from below map pocket. 6. If equipped, remove window crank. 7. Using a trim stick, remove screw cover from switch panel. 8. Remove screws attaching switch panel to door trim. Fig.32 Front Door Switch Panel 9. Remove power accessary switch from door trim. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6296 10. Disconnect power switch from wire connector. Fig.33 Memory Seat/Mirror Switch 11. If equipped, using a small, flat bladed pry tool, remove memory seat/mirror switch and disconnect wire connector. 12. If equipped, remove screw holding door trim to door panel from behind inside latch release handle. Fig.34 Front Door Trim Panel 13. Disengage clips attaching door trim to door frame around perimeter of panel. 14. Lift trim panel upward to disengage flange from inner belt molding at top of door. 15. Tilt top of trim panel away from door to gain access to latch linkage. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6297 Fig.35 Inside Door Handle Linkage 16. Disengage clip attaching linkage rod to inside latch release handle. 17. Separate linkage rod from latch handle. 18. Remove front door trim panel from vehicle. INSTALLATION 1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in position on latch handle. 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door. 6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect power switch into wire connector. 9. Place power accessary switch in position on door trim. 10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11. Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to door inside map pocket. 15. If equipped, install screw to attach door pull cup to inner door panel. 16. If equipped, install screws to attach door assist handle to inner door panel. 17. Connect wire connector into courtesy lamp. 18. Install lamp in door trim. Left D-Pillar Trim Panel LEFT D-PILLAR TRIM PANEL REMOVAL 1. Remove rear header trim cover. 2. Remove liftgate sill plate. 3. Remove second rear seat belt turning loop on long wheel base vehicle. 4. Remove bolt holding second rear seat belt lower anchor to quarter on short wheel base vehicle. 5. Remove jack storage cover. 6. Remove screws holding trim panel to D-pillar Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6298 Left Quarter and D-Pillar Trim Panels - LWB 3 Door, Left Quarter and D-Pillar Trim Panels - LWB 4 Door Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6299 Left Quarter and D-Pillar Trim Panels - SWB 7. Disengage hidden clips holding trim to D-pillar. 8. Disengage speaker wire connector, if equipped. 9. Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle. 10. Separate D-pillar trim from vehicle. INSTALLATION 1. Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle. 2. Position D-pillar trim panel on vehicle. 3. Engage speaker wire connector to speaker, if equipped. 4. Align locating pins on backside of trim panel to mating holes in inner quarter panel. 5. Engage hidden clips to hold trim to D-pillar. 6. Install screws to hold trim to D-pillar. 7. Install jack storage cover. 8. Install bolt to hold second rear seat belt lower anchor to quarter on short wheel base vehicle. 9. Install second rear seat belt turning loop on long wheel base vehicle. 10. Install liftgate sill plate. 11. Install rear header trim cover. Quarter Trim Bolster QUARTER TRIM BOLSTER The speaker grille in the quarter trim bolster is not removable. The trim bolster must removed to service the speaker. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6300 REMOVAL 1. Disengage hidden clips holding trim bolster to quarter trim panel. 2. Disengage hook retainer holding front of trim bolster to quarter trim panel, if applicable. 3. Separate quarter trim bolster from vehicle. Left Quarter Trim Bolster - LWB 4 Door Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6301 Left Quarter Trim Bolster SWB and LWB 3 Door INSTALLATION 1. Place quarter trim bolster in position on vehicle. 2. Engage hook retainer to hold front of trim bolster to quarter trim panel, if applicable. 3. Engage hidden clips to hold trim bolster to quarter trim panel. Right D-Pillar Trim Panel RIGHT D-PILLAR TRIM PANEL REMOVAL 1. Remove rear header trim cover. 2. Remove liftgate Sill plate. 3. Remove second rear seat belt turning loop on long wheel base vehicle. 4. Remove bolt holding second rear seat belt, if equipped, anchor to quarter on short wheel base vehicle. 5. Remove quarter trim bolster on short wheel base vehicle. 6. Remove screws holding trim panel to attaching bracket on short wheel base vehicle. 7. Disengage hidden clips holding trim to D-pillar. 8. Separate D-pillar trim panel from D-pillar. 9. Disengage speaker wire connector, if equipped. 10. Pass second rear seat belt, if equipped, through slot in trim panel on short wheel base vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6302 11. Separate D-pillar trim from vehicle. Right Quarter and D-Pillar Trim Panels - SWB Right Quarter and D-Pillar Trim Panels - LWB with out A/C Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Lower Extension > Page 6303 Right Quarter and D-Pillar Trim Panels - LWB with A/C INSTALLATION 1. Position D-pillar trim on vehicle. 2. Pass second rear seat belt, if equipped, through slot in trim panel on short wheel base vehicle. 3. Engage speaker wire connector to speaker, if equipped. 4. Align locating pins on backside of trim panel to mating holes in D-pillar. 5. Engage hidden clips to hold trim to D-pillar. 6. Install screws to hold trim panel to attaching bracket on short wheel base vehicle. 7. Install quarter trim bolster on short wheel base vehicle. 8. Install bolt to hold second rear seat belt, if equipped, anchor to quarter on short wheel base vehicle. 9. Install second rear seat belt turning loop on long wheel base vehicle. 10. Install liftgate sill plate. 11. Install rear header trim cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 6309 Keyless Entry Module: Adjustments The content of this article reflects the changes called out by TSB 26-09-99. PROGRAMMING RKE MODULE 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and was successful. 7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify that the RKE module will no longer accept additional Vehicle Access Code(s). 9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will require programming. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 6310 Keyless Entry Module: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws holding RKE module to instrument panel. RKE Module 4. Disconnect wire connector from RKE module. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications Keyless Entry Transmitter Battery: Specifications The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean and dry. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound Power Door Lock Actuator: Customer Interest Sliding Door Power Lock Actuator - Chatter Sound NUMBER: 23-042-00 GROUP: Body DATE: Nov. 3, 2000 SUBJECT: Sliding Door Power Lock Actuator Chatter Sound OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to eliminate the plunger lifting away from the lock lever when in the lock position. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power lock feature is repeatedly activated. DIAGNOSIS: Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair Procedure. NOTE: REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the 2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and available on MDS2). 2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control. 3. Remove the latch/lock control cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound > Page 6327 4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA. 5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator grommet as shown in (Fig. 1). 6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should be heard from the actuator and the plunger should remain held under the lock lever during and after actuation. 7. Install the latch/lock control cover. 8. Install the water shield. 9. Install the sliding door interior trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-03-99 > Feb > 99 > Power Door Lock Motor - Whirling Noise Power Door Lock Actuator: Customer Interest Power Door Lock Motor - Whirling Noise NUMBER: 23-03-99 GROUP: Body DATE: Feb. 12, 1999 SUBJECT: Power Door Lock Motor Whirling Noise MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to help improve Fix It Right (FIR) scores. 1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking to discover any power door lock motors that make a whirling noise, even intermittently. 2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise by placing your ear near the rear of the suspect front door, then activate the power door locks to confirm which side the whirling noise is coming from. 3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors open) and activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door. (leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor Operation Time Schedule for operation number, time allowance and failure code. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound Power Door Lock Actuator: All Technical Service Bulletins Sliding Door Power Lock Actuator Chatter Sound NUMBER: 23-042-00 GROUP: Body DATE: Nov. 3, 2000 SUBJECT: Sliding Door Power Lock Actuator Chatter Sound OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to eliminate the plunger lifting away from the lock lever when in the lock position. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power lock feature is repeatedly activated. DIAGNOSIS: Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair Procedure. NOTE: REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the 2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and available on MDS2). 2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control. 3. Remove the latch/lock control cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound > Page 6337 4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA. 5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator grommet as shown in (Fig. 1). 6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should be heard from the actuator and the plunger should remain held under the lock lever during and after actuation. 7. Install the latch/lock control cover. 8. Install the water shield. 9. Install the sliding door interior trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-03-99 > Feb > 99 > Power Door Lock Motor - Whirling Noise Power Door Lock Actuator: All Technical Service Bulletins Power Door Lock Motor - Whirling Noise NUMBER: 23-03-99 GROUP: Body DATE: Feb. 12, 1999 SUBJECT: Power Door Lock Motor Whirling Noise MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to help improve Fix It Right (FIR) scores. 1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking to discover any power door lock motors that make a whirling noise, even intermittently. 2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise by placing your ear near the rear of the suspect front door, then activate the power door locks to confirm which side the whirling noise is coming from. 3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors open) and activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door. (leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor Operation Time Schedule for operation number, time allowance and failure code. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 6342 Power Door Lock Actuator: Diagrams Driver Door Lock Motor Passenger Door Lock Motor Right (Rear) Sliding Door Lock Motor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 6343 Power Door Lock Actuator: Testing and Inspection Verify battery condition before testing door lock motor(s), refer to Battery for proper diagnosis procedures. To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem may be caused by a shorted motor, a relay or a bad switch. Disconnecting the defective motor will allow the others to work. Door Lock Motor Connector Pin Location Front Door Lock Motor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 6344 Lift Gate Release Assembly To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a 12 volt power source to the positive pin of the lock motor and a ground wire to the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these results are NOT obtained, replace the motor. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Liftgate Lock Motor Power Door Lock Actuator: Service and Repair Liftgate Lock Motor REMOVAL Negative Battery Cable 1. Disconnect and isolate the negative battery cable. 2. Remove liftgate trim panel. Liftgate Lock Motor 3. Remove bolts holding liftgate lock motor to liftgate. 4. Disconnect the wire connector from power lock motor. 5. Disconnect the liftgate lock motor from outside handle lock link. 6. Remove the liftgate lock motor from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Liftgate Lock Motor > Page 6347 Power Door Lock Actuator: Service and Repair Sliding Door Lock Motor REMOVAL Negative Battery Cable 1. Disconnect and isolate the negative battery cable. 2. Remove sliding door trim panel. 3. Remove sound pad as necessary 4. Remove latch/lock control cover. 5. Remove latch/lock control. Sliding Door Lock Motor 6. Remove screws holding door lock motor to latch/lock control. 7. Remove lock motor from control. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6351 Power Door Lock Relay: Diagrams Junction Block Door Lock Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6352 Door Unlock Relay Driver Door Unlock Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6356 Power Door Lock Switch: Testing and Inspection 1. Remove door lock/power window switch bezel assembly from door. Refer to Power Door Lock Switch Replacement. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch Door Lock Switch Test 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. Refer to Door Lock Switch Test. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the parameters shown replace the door lock switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6357 Power Door Lock Switch: Service and Repair The Power Door Lock Switch is the only serviceable part on the power door lock / window switch bezel.The window switches, window lock - out, and power vent window switch is serviced with the bezel. REMOVAL Negative Battery Cable 1. Disconnect and isolate the negative battery cable. 2. Open left door, remove screw cover near inside door release handle. 3. Remove two screws to door lock / window switch bezel. One under the screw cover removed in previous step and one to the rear of the front door vent opening. 4. Pull out and up on bezel to release from door trim panel. 5. Disconnect door lock switch connector. 6. Remove two door lock switch retaining screws and remove switch from vehicle. INSTALLATION 1. For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation Heated Element: Description and Operation Heated Mirror Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the rear window defogger is ON. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation > Page 6362 Heated Element: Testing and Inspection Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the rear window defogger is ON. TEST PROCEDURE 1. The mirror should be warm to the touch. 2. If not, check the 10 amp fuse (12) in the junction block behind the instrument panel to the left of the steering column. 3. Test voltage at rear window defogger switch. - If no voltage repair wire. Power Mirror Test - Apply voltage to one wire and ground the other. Mirror should become warm to the touch. - If not remove mirror glass and test the wires for continuity. If no continuity repair wires. - If wires are OK, replace mirror glass. - To test defogger switch refer to Electrically Heated Systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection Power Mirror Motor: Testing and Inspection 1. Remove Power Mirror Switch. Refer to Instrument Panel and Systems, Power Mirror Switch Replacement. 2. Disconnect wiring harness connector to the power mirror switch and headlamp switch. 3. Using two jumper wires: - Connect one to a 12-volt source - Connect the other to a good body ground Power Mirror Test - Refer to the Mirror Test Chart for wire hookups at the switch connector. 4. If results shown in table are not obtained, check for broken or shorted circuit, or replace mirror assembly as necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection 1. Remove power mirror switch. Refer to Instrument Panel and Systems for Replacement Procedures. 2. Disconnect wiring harness at switch connector. Mirror Switch Test 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Power Mirror Switch: Service and Repair Power Mirror Switch REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. Power Mirror Switch 3. Disconnect wire connector from back of power mirror switch. 4. Disengage lock tabs above and below the mirror switch. 5. Pull power mirror switch from headlamp switch bezel. The power mirror switch bezel is mounted to the bottom of the instrument cluster bezel. 6. Remove power mirror switch. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 6371 Power Mirror/Window Switch Refer to Instrument Panel and Systems for service procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 6372 Power Mirror Switch: Service and Repair Power Mirror Switch Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove instrument cluster bezel. Power Mirror Switch Lamp 4. Rotate bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from back of power mirror switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams Remote Keyless Entry (RKE) Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 6377 Keyless Entry Module: Adjustments The content of this article reflects the changes called out by TSB 26-09-99. PROGRAMMING RKE MODULE 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and was successful. 7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8. Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify that the RKE module will no longer accept additional Vehicle Access Code(s). 9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will require programming. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 6378 Keyless Entry Module: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws holding RKE module to instrument panel. RKE Module 4. Disconnect wire connector from RKE module. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6382 Power Door Lock Relay: Diagrams Junction Block Door Lock Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6383 Door Unlock Relay Driver Door Unlock Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range NO: 08-44-98 GROUP: Electrical DATE: Dec. 11, 1998 SUBJECT: Memory Power Seat Travel Range MODELS: 1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand Cherokee 1996-1998 (ZG) Grand Cherokee (International Market) DISCUSSION: The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motor end, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, no change in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not run into a stall condition (end of travel). The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when something is stuck under or behind the seat that causes the seat to stop moving). These soft stops can prevent the seat from being able to have memory positions set over the full range of travel. Also, positions that were previously programmed to locations beyond an updated soft stop limit will not be recalled as they are "out of range." When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat operation. There are two potential reasons for intermittent memory functioning of the seats. The first possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in the seat's path or a person shifting their body while a power seat motor is in operation.) The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can be caused by a poor connection at pin 23 of the P34 connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locks out" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for fully seated and clean contacts. To check and reset the soft stop limits in memory, use the control switches on the side of the seat to move the seat in one direction to the end of travel, then energize the seat again in the same direction until it stops and for three additional seconds after it stops. The amount that the seat moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat this procedure for each of the directions of movement (one at a time). NOTE: IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE MANUAL). POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation SYSTEM OPERATION The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules are used in the vehicle, one for each front seat. The HSCM for each seat is installed on front portion of each cushion pan. The wire harness connector is secured by an integral clip to the inside surface of the outboard seat cushion frame. Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery feed, and a ground. The only HSCM output is the feed for the seat heating elements. The HSCM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 6391 Seat Heater Control Module: Testing and Inspection Before testing the heated seat control module, test the heated seat switch, the heated seat elements, and the heated seat sensor as described. If testing of the heated seat switch, elements, and sensor reveals no problems, proceed as follows. 1. Replace the heated seat control module with a known good unit and test the operation of the heated seats. If OK, discard the faulty heated seat control module. If not OK, go to Step 2. 2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat sensor to the heated seat control module. Repair any short or open circuits as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 6392 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5. Remove module from seat cushion pan. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 23-11-00 > Mar > 00 > Roof Panel Wavy or has Depressions Roof Rack Frame: Customer Interest Roof Panel - Wavy or has Depressions BULLETIN NUMBER: 23-11-00 GROUP: Body DATE: Mar.24, 2000 SUBJECT: Roof Panel Wavy Or Has Depressions MODELS: 1996 - 2000 (NS) Town & County/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-28-96, DATED MAY 3, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. OVERVIEW: This bulletin involves applying heat to the roof panel to remove depression(s). This Repair Procedure is not intended to be used to correct any type of impact/damage caused dents. SYMPTOM/CONDITION: The roof panel surface exhibits waviness or depression(s) near the front of the character features or skid strip for roof rack equipped vehicles. Typically the shape of the depression or waviness will be elliptical or along a line across the vehicle. The depression(s) will go away on their own as the vehicle is exposed to higher ambient temperatures and sun load. DIAGNOSIS: While standing in front of the vehicle, visually inspect the roof panel, if any depression(s) or waviness is seen in one or both areas shown in Figure 1, perform the following Repair Procedure only if the customer is unwilling to wait for higher ambient temperatures to remove the depression(s). EQUIPMENT REQUIRED. Heat Gun such as Pentastar Service Equipment (PSE) W-PH12OO REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 23-11-00 > Mar > 00 > Roof Panel Wavy or has Depressions > Page 6402 Figure 1 1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped. 2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop" when the depression removal is complete. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions Roof Rack Frame: All Technical Service Bulletins Roof Panel - Wavy or has Depressions BULLETIN NUMBER: 23-11-00 GROUP: Body DATE: Mar.24, 2000 SUBJECT: Roof Panel Wavy Or Has Depressions MODELS: 1996 - 2000 (NS) Town & County/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-28-96, DATED MAY 3, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. OVERVIEW: This bulletin involves applying heat to the roof panel to remove depression(s). This Repair Procedure is not intended to be used to correct any type of impact/damage caused dents. SYMPTOM/CONDITION: The roof panel surface exhibits waviness or depression(s) near the front of the character features or skid strip for roof rack equipped vehicles. Typically the shape of the depression or waviness will be elliptical or along a line across the vehicle. The depression(s) will go away on their own as the vehicle is exposed to higher ambient temperatures and sun load. DIAGNOSIS: While standing in front of the vehicle, visually inspect the roof panel, if any depression(s) or waviness is seen in one or both areas shown in Figure 1, perform the following Repair Procedure only if the customer is unwilling to wait for higher ambient temperatures to remove the depression(s). EQUIPMENT REQUIRED. Heat Gun such as Pentastar Service Equipment (PSE) W-PH12OO REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions > Page 6408 Figure 1 1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped. 2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop" when the depression removal is complete. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6414 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6415 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6416 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6417 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6418 TIME ALLOWANCE: FAILURE CODE: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range NO: 08-44-98 GROUP: Electrical DATE: Dec. 11, 1998 SUBJECT: Memory Power Seat Travel Range MODELS: 1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand Cherokee 1996-1998 (ZG) Grand Cherokee (International Market) DISCUSSION: The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motor end, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, no change in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not run into a stall condition (end of travel). The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when something is stuck under or behind the seat that causes the seat to stop moving). These soft stops can prevent the seat from being able to have memory positions set over the full range of travel. Also, positions that were previously programmed to locations beyond an updated soft stop limit will not be recalled as they are "out of range." When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat operation. There are two potential reasons for intermittent memory functioning of the seats. The first possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in the seat's path or a person shifting their body while a power seat motor is in operation.) The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can be caused by a poor connection at pin 23 of the P34 connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locks out" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for fully seated and clean contacts. To check and reset the soft stop limits in memory, use the control switches on the side of the seat to move the seat in one direction to the end of travel, then energize the seat again in the same direction until it stops and for three additional seconds after it stops. The amount that the seat moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat this procedure for each of the directions of movement (one at a time). NOTE: IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE MANUAL). POLICY: Information Only Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and Inspection Power Seat Motor: Testing and Inspection 1. Remove power seat switch. Refer to Seat Switch Replacement. 2. Disconnect wire connector. 3. Using a voltmeter check for battery voltage at Pin 5. Using an ohmmeter, check Pin 1 for ground. Seat Motor Test 4. To test the seat motors, verify proper seat responses. Using two jumper wires, connect one to a battery supply and the other to a ground. Connect the other ends to the seat wire harness connector as described. If any motor fails to operate, check wire connectors to the motor. If not OK, repair as necessary If OK, replace power seat adjuster. Refer to Power Seat Adjuster Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and Inspection > Page 6426 Power Seat Motor: Service and Repair The Power Seat Adjuster and motors are serviced as an assembly. REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove seat from vehicle. 3. Remove seat cushion pan. 4. Remove nut holding recliner to seat back frame. 5. Remove bolts holding seat back frame to seat track. 6. Remove stud on seat back frame from recliner. 7. Remove seat back from recliner. INSTALLATION Transfer the power recliner, wire harness and trim covers to replacement power seat adjuster. 1. For installation, reverse the above procedures. 2. Reinstall seat in vehicle. Tighten fasteners to 60 Nm (44 ft. lbs.) torque. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch: Testing and Inspection 1. Remove seat switch from seat. Refer to Seat Switch Replacement. Seat Switch Test 2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the switch positions, replace switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 6430 Power Seat Switch: Service and Repair REMOVAL AND INSTALLATION Negative Battery Cable 1. Disconnect and isolate the battery negative cable. Bucket See Cushion Side Cover Remove/Install 2. Remove seat cushion side cover. Set Switch Wire Connector 3. Disconnect the wire connector to the seat switch and remove side cover from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Testing and Inspection Seat Cushion: Testing and Inspection 1. Disconnect and isolate the battery negative cable. Unplug the 4-way heated seat cushion wire harness connector. 2. Check for continuity between the two heated seat driver circuit cavities of the seat cushion cover half of the heated seat cushion wire harness connector. There should be continuity If OK, go to Step 3. If not OK, replace the faulty seat cushion cover. 3. Check for continuity between one of the heated seat driver circuit cavities of the seat cushion cover half of the heated seat cushion wire harness connector and the seat cushion frame. There should be no continuity. If OK, go to the Seat Back test. If not OK, replace the faulty seat cushion cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions Seat Heater: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions NUMBER: 26-04-99 GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-9105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 6438 8N-4 Revision to the Body Control Module connector pin-out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 6439 8W-80-13 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Page 6440 Seat Heater: Description and Operation The content of this article reflects the changes called out by TSB 26-04-99. INTRODUCTION Individually controlled electrically heated front seats are available factory-installed optional equipment. The seat heaters will only operate when the ignition switch is in the On position, and the surface temperature at the front seat heating element sensors is below the designed temperature set points of the system. The heated seat system will not operate in ambient temperatures greater than about 32 °C (90 °F). There are separate three-position switches for each front seat located in the inboard seat cushion side shield. An Off, Low, or High position can be selected with each switch, and Light-Emitting Diodes (LED) for each switch illuminate to give a visual indication that the system is turned on. The Low heat position set point is about 32 °C (90 °F), and the High heat position set point is about 38 °C (100 °F). Each switch controls a Heated Seat Control Module (HSCM) mounted to the seat cushion frame under each front seat. When a seat heater is turned on, a sensor located near the seat cushion electric heater element provides the HSCM with an input indicating the surface temperature of the seat cushion. If the surface temperature input is below the temperature set point for the selected Low or High switch position, a relay within the HSCM energizes the heating elements in the seat cushion and back. When the sensor input indicates the correct temperature set point has been achieved, the HSCM de-energizes the relay The HSCM will continue to cycle the relay as needed to maintain the temperature set point. The HSCM will automatically turn off the heating elements if it detects an open in the sensor circuit, or a short in the heating element circuit causing an excessive current draw. The system is also turned off automatically when the ignition switch is turned to the Off position. The control circuit operates on ignition switched battery feed through a fuse in the junction block. The heating elements operate on battery feed supplied through the power seat circuit breaker located in the wire harness under the driver's seat. SYSTEM OPERATION Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat, one for the seat cushion and the other for the seat back. The two element for each seat are connected in series with the HSCM. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat, and it is integrated into the seat cushion heating element. The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which are serviced individually. The heating elements and temperature sensor cannot be repaired and, if faulty or damaged, the affected seat cover assembly must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System Seat Heater: Testing and Inspection Heated Seat System Before testing the individual components in the heated seat system, check the following: - If the heated seat switch LED doesn't light with the ignition switch in the On position and the heated seat switch in the Low or High position, check the fuse in the junction block. If the Fuse is OK, test the heated seat switch as described. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. - If the heated seat switch LED lights, but the heating elements don't heat, check the circuit breaker in the junction block. If the circuit breaker is OK, test the heated seat elements as described. If not OK, replace the faulty circuit breaker. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 6443 Seat Heater: Testing and Inspection Heated Seat Element The wire harness connectors for the seat cushion and seat back heating elements are located under the seat, near the rear edge of the seat cushion frame. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation SYSTEM OPERATION The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules are used in the vehicle, one for each front seat. The HSCM for each seat is installed on front portion of each cushion pan. The wire harness connector is secured by an integral clip to the inside surface of the outboard seat cushion frame. Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery feed, and a ground. The only HSCM output is the feed for the seat heating elements. The HSCM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 6447 Seat Heater Control Module: Testing and Inspection Before testing the heated seat control module, test the heated seat switch, the heated seat elements, and the heated seat sensor as described. If testing of the heated seat switch, elements, and sensor reveals no problems, proceed as follows. 1. Replace the heated seat control module with a known good unit and test the operation of the heated seats. If OK, discard the faulty heated seat control module. If not OK, go to Step 2. 2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat sensor to the heated seat control module. Repair any short or open circuits as required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 6448 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5. Remove module from seat cushion pan. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation SYSTEM OPERATION The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If either switch or LED is faulty, the switch must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 6452 Seat Heater Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion side cover. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open circuit as required. 4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK, replace the faulty switch. 5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 6453 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755), gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out switch from rear of switch bezel. 5. Remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description and Operation Seat Heater Thermostat: Description and Operation SYSTEM OPERATION Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat, one for the seat cushion and the other for the seat back. The two element for each seat are connected in series with the HSCM. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat, and it is integrated into the seat cushion heating element. The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which are serviced individually. The heating elements and temperature sensor cannot be repaired and, if faulty or damaged, the affected seat cover assembly must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description and Operation > Page 6457 Seat Heater Thermostat: Testing and Inspection The wire harness connector for the seat cushion heating element and sensor are located under the seat, near the rear edge of the seat cushion frame. 1. Disconnect and isolate the battery negative cable. Unplug the 4-way heated seat cushion wire harness connector. 2. Using an ohmmeter, check the resistance between the heated seat switch output circuit cavity and the ground circuit cavity of the seat cushion cover half of the heated seat cushion wire harness connector. The sensor resistance should be between 2 kilo ohms and 200 kilo ohms. If OK, test the heated seat control module as described. If not OK, replace the faulty seat cushion cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles Seat Latch: Customer Interest Quad Seat Easy Entry Latch - Rattles NUMBER: 23-27-99 GROUP: Body DATE: Jul. 23, 1999 SUBJECT: Quad Seat Easy Entry Latch Rattle OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: Rattle noise is heard when driving DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure. PARTS REQUIRED: 1 04773968 Tape, Flock 1 04318063 Grease REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the mylar tape from the easy entry latch striker (Fig. 1) 2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with isopropyl alcohol. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 6466 3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2). 4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker. 5. Return the quad seat to its latched/normal position. 6. Repeat for the other quad seat. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles Seat Latch: All Technical Service Bulletins Quad Seat Easy Entry Latch - Rattles NUMBER: 23-27-99 GROUP: Body DATE: Jul. 23, 1999 SUBJECT: Quad Seat Easy Entry Latch Rattle OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: Rattle noise is heard when driving DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure. PARTS REQUIRED: 1 04773968 Tape, Flock 1 04318063 Grease REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the mylar tape from the easy entry latch striker (Fig. 1) 2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with isopropyl alcohol. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 6472 3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2). 4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker. 5. Return the quad seat to its latched/normal position. 6. Repeat for the other quad seat. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. Negative Battery Cable 2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6481 Power Door Lock Switch: Testing and Inspection 1. Remove door lock/power window switch bezel assembly from door. Refer to Power Door Lock Switch Replacement. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch Door Lock Switch Test 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. Refer to Door Lock Switch Test. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the parameters shown replace the door lock switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6482 Power Door Lock Switch: Service and Repair The Power Door Lock Switch is the only serviceable part on the power door lock / window switch bezel.The window switches, window lock - out, and power vent window switch is serviced with the bezel. REMOVAL Negative Battery Cable 1. Disconnect and isolate the negative battery cable. 2. Open left door, remove screw cover near inside door release handle. 3. Remove two screws to door lock / window switch bezel. One under the screw cover removed in previous step and one to the rear of the front door vent opening. 4. Pull out and up on bezel to release from door trim panel. 5. Disconnect door lock switch connector. 6. Remove two door lock switch retaining screws and remove switch from vehicle. INSTALLATION 1. For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection 1. Remove power mirror switch. Refer to Instrument Panel and Systems for Replacement Procedures. 2. Disconnect wiring harness at switch connector. Mirror Switch Test 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Power Mirror Switch: Service and Repair Power Mirror Switch REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. Power Mirror Switch 3. Disconnect wire connector from back of power mirror switch. 4. Disengage lock tabs above and below the mirror switch. 5. Pull power mirror switch from headlamp switch bezel. The power mirror switch bezel is mounted to the bottom of the instrument cluster bezel. 6. Remove power mirror switch. INSTALLATION For installation, reverse the above procedures. REMOVAL AND INSTALLATION Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 6488 Power Mirror/Window Switch Refer to Instrument Panel and Systems for service procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 6489 Power Mirror Switch: Service and Repair Power Mirror Switch Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove instrument cluster bezel. Power Mirror Switch Lamp 4. Rotate bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from back of power mirror switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch: Testing and Inspection 1. Remove seat switch from seat. Refer to Seat Switch Replacement. Seat Switch Test 2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the switch positions, replace switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 6493 Power Seat Switch: Service and Repair REMOVAL AND INSTALLATION Negative Battery Cable 1. Disconnect and isolate the battery negative cable. Bucket See Cushion Side Cover Remove/Install 2. Remove seat cushion side cover. Set Switch Wire Connector 3. Disconnect the wire connector to the seat switch and remove side cover from vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation SYSTEM OPERATION The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If either switch or LED is faulty, the switch must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 6497 Seat Heater Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion side cover. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open circuit as required. 4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK, replace the faulty switch. 5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 6498 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755), gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out switch from rear of switch bezel. 5. Remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Liftgate Ajar Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 6510 TIME ALLOWANCE FAILURE CODE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 6516 TIME ALLOWANCE FAILURE CODE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange Weatherstrip: Customer Interest Door Weatherstrip - Falls Off Mounting Flange NO: 23-34-98 GROUP: Body DATE: Aug. 7, 1998 SUBJECT: Front Door Body Mounted Weatherstrip Retention MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The front door body mounted weatherstrip falls off mounting flange, usually along the top of the door opening. DIAGNOSIS: Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or pulls off easily, perform the Repair Procedure. NOTE: THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP IS REMOVED FOR ANY REASON. PARTS REQUIRED: AR NPN Isopropyl Alcohol REPAIR PROCEDURE: This bulletin involves removing the slip coating on the weatherstrip and mounting flange. 1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the weatherstrip installed. 2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the seal mounts to. 3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as possible without bending it open. If done properly, there will be some black residue on the rag from the weatherstrip. 4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure. 5. Reinstall the weatherstrip on the flange, make sure it is fully seated. 6. Repeat steps 1 through 5 for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-09-92 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Falls Off Mounting Flange NO: 23-34-98 GROUP: Body DATE: Aug. 7, 1998 SUBJECT: Front Door Body Mounted Weatherstrip Retention MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The front door body mounted weatherstrip falls off mounting flange, usually along the top of the door opening. DIAGNOSIS: Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or pulls off easily, perform the Repair Procedure. NOTE: THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP IS REMOVED FOR ANY REASON. PARTS REQUIRED: AR NPN Isopropyl Alcohol REPAIR PROCEDURE: This bulletin involves removing the slip coating on the weatherstrip and mounting flange. 1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the weatherstrip installed. 2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the seal mounts to. 3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as possible without bending it open. If done properly, there will be some black residue on the rag from the weatherstrip. 4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure. 5. Reinstall the weatherstrip on the flange, make sure it is fully seated. 6. Repeat steps 1 through 5 for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-09-92 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6534 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6535 Cruise Control Servo: Description and Operation DESCRIPTION The servo unit consists of a solenoid valve body, and a vacuum chamber. OPERATION The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6536 Cruise Control Servo: Testing and Inspection 1. Turn ignition switch to the ON position without starting engine. Activate speed control ON switch. Fig. 4 Servo Harness Connector 2. Disconnect the four-way electrical connector and the vacuum harness at the servo. 3. Connect a jumper wire from Pin 3 of the servo to Pin 3 of the wire connector. 4. Ground Pins 2 and 4 in the servo. Do not connect pin 1. 5. Connect a hand held vacuum pump to the vacuum nipple and apply 10 - 15 inches of vacuum. 6. If servo pulls cable, replace servo. 7. Ground Pin 1 on servo. 8. Check that the throttle cable pulls in and holds as long as the vacuum pump is connected. After one minute, check if cable is still holding. If cable does not hold replace the servo. 9. Disconnect jumper from pin 3. Cable should return to rest position. If not, replace servo. 10. Connect 4 way electrical connector and vacuum harness to servo. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6537 Cruise Control Servo: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Remove air cleaner resonator. Fig. 11 Speed Control Cable End 3. Disconnect the throttle and speed control cable ends from throttle body. Speed Control Cable Case And Vacuum Line - Typical 4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Disconnect vacuum line from nipple on air intake plenum. 6. Remove tie wrap holding vacuum line, throttle cable, and speed control cable together. Speed Control Servo 7. Remove bolt holding speed control servo to side of battery tray/vacuum reservoir. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6538 8. Remove speed control servo from battery tray. 9. Disconnect wire connector from speed control servo. 10. Disconnect vacuum line from speed control servo that leads to the battery tray/vacuum reservoir. 11. Remove speed control servo. INSTALLATION Transfer speed control cable to replacement speed control servo. Reverse the preceding operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation DESCRIPTION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. OPERATION This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 6542 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Remove air cleaner resonator. Fig. 11 Speed Control Cable End 3. Disconnect throttle and speed control cable ends from throttle body. Speed Control Cable 4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Remove tie wrap holding vacuum line, throttle cable, and speed control cable together. 6. Remove nuts holding speed control cable case to servo. 7. Remove cable case from servo. 8. Remove hairpin clip holding cable end to servo diaphragm. INSTALLATION Reverse the preceding operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Speed Control Switches Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6546 Cruise Control Switch: Description and Operation DESCRIPTION There are two separate switch pods that operate the speed control system. OPERATION The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6547 Cruise Control Switch: Testing and Inspection Refer to the appropriate Powertrain Diagnostics for switch test values. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6548 Cruise Control Switch: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove airbag/horn pad from steering wheel, refer to Airbags and Seat Belts/Airbags for proper procedures. 4. Disconnect wire connector from horn switch, airbag, and speed control switches. Speed Control Switches 5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control switch from airbag/horn pad. INSTALLATION Reverse the preceding operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades Cruise Control Vacuum Reservoir: Customer Interest Speed Control - Does Not Maintain Speed on Grades NUMBER: 08-27-99 GROUP: Electrical EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because of speed control vacuum loss while on up hill grade. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE. SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under low manifold vacuum conditions. The valve may become contaminated and cause it not to seal intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade. DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of vacuum leak is found, perform the Repair Procedure. PARTS REQUIRED: 1 04716740AB Tray, Battery/Vacuum Reservoir EQUIPMENT REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades > Page 6557 Hand Vacuum Pump REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the nut and two bolts from the battery tray, Figure 1. 2. Remove the speed control servo attaching bolt from the battery tray. 3. Disconnect the vacuum lines from the battery tray vacuum reservoir. 4. Remove the battery tray from the vehicle and discard. 5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB. 6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.). 7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.). 8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.) 9. Connect the positive and negative battery terminals. 10. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-08-05-90 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades Cruise Control Vacuum Reservoir: All Technical Service Bulletins Speed Control - Does Not Maintain Speed on Grades NUMBER: 08-27-99 GROUP: Electrical EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because of speed control vacuum loss while on up hill grade. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE. SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under low manifold vacuum conditions. The valve may become contaminated and cause it not to seal intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade. DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of vacuum leak is found, perform the Repair Procedure. PARTS REQUIRED: 1 04716740AB Tray, Battery/Vacuum Reservoir EQUIPMENT REQUIRED: Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades > Page 6563 Hand Vacuum Pump REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the nut and two bolts from the battery tray, Figure 1. 2. Remove the speed control servo attaching bolt from the battery tray. 3. Disconnect the vacuum lines from the battery tray vacuum reservoir. 4. Remove the battery tray from the vehicle and discard. 5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB. 6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.). 7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.). 8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.) 9. Connect the positive and negative battery terminals. 10. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-08-05-90 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Page 6564 Cruise Control Vacuum Reservoir: Description and Operation OPERATION The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Page 6565 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove battery, Refer to Battery Replacement. 3. Remove battery tray. 4. Disconnect vacuum hoses from vacuum reservoir INSTALLATION 1. Connect vacuum hoses to vacuum reservoir. 2. Install battery tray 3. Install battery, Refer to Battery Replacement. 4. Connect negative cable to battery. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and Operation Cruise Control Vacuum Solenoid: Description and Operation SPEED CONTROL SOLENOIDS-PCM OUTPUT The speed control vacuum and vent solenoids are operated by the PCM. When the PCM supplies a ground to the vacuum and vent solenoids, the speed control system opens the throttle plate. When the PCM removes the ground from the vacuum and vent solenoids, the throttle blade closes. The PCM balances the two solenoids to maintain the set speed. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Speed Control Switches Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6573 Cruise Control Switch: Description and Operation DESCRIPTION There are two separate switch pods that operate the speed control system. OPERATION The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6574 Cruise Control Switch: Testing and Inspection Refer to the appropriate Powertrain Diagnostics for switch test values. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6575 Cruise Control Switch: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove airbag/horn pad from steering wheel, refer to Airbags and Seat Belts/Airbags for proper procedures. 4. Disconnect wire connector from horn switch, airbag, and speed control switches. Speed Control Switches 5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control switch from airbag/horn pad. INSTALLATION Reverse the preceding operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 6584 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 6590 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Page 6591 Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation OPERATION The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a Vehicle Speed Sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Diagnostic Procedures for diagnosis and testing of this component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Page 6592 Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection For diagnosis and testing of the Vehicle Speed Signal (VSS), refer to the appropriate Powertrain Diagnostic Procedures. Also refer to the DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 6601 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 6607 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Page 6608 Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation OPERATION The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a Vehicle Speed Sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Diagnostic Procedures for diagnosis and testing of this component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Page 6609 Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection For diagnosis and testing of the Vehicle Speed Signal (VSS), refer to the appropriate Powertrain Diagnostic Procedures. Also refer to the DRB scan tool. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The amber ABS warning lamp is located on the right side of the message center located at the top of the instrument panel. When the ignition key is turned to the ON position, the amber ABS warning lamp is lit until the CAB completes its self-tests and turns off the lamp (approximately 4 seconds). The amber ABS warning lamp will illuminate when the CAB detects a condition that results in the shutdown of ABS function, or when the body controller does not receive a CCD message from the CAB. The CAB turns on the amber ABS warning lamp by grounding the circuit. Under most conditions, when the amber ABS warning lamp is on, only the ABS function of the brake system is affected; the base brake system and the ability to stop the vehicle are not affected. The amber ABS warning lamp is controlled by the CAB and the body controller through a diode located in the junction block. The CAB and body controller control the amber ABS warning lamp by directly grounding the circuit. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Audible Warning Device: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Chime System Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6637 Audible Warning Device: Description and Operation CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened, The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The red BRAKE warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank position. The warning lamp bulb is supplied a 12-volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the parking brake switch, the fluid level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the crank position. The Brake Fluid Level switch is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the switch is to provide the driver with an early warning that brake fluid level in the master cylinder fluid reservoir has dropped to below normal. This may indicate: Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. - Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level switch closes to ground the brake warning light circuit. This will turn on the red BRAKE warning Light. At this time, the master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Cigarette Lighter Relay > Component Information > Locations Cigarette Lighter Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Cigarette Lighter Relay > Component Information > Locations > Page 6645 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Cigarette Lighter Relay > Component Information > Locations > Page 6646 Cigarette Lighter Relay: Diagrams Power Distribution Center Cigar Lighter/Accessory Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Compass/Mini-Trip Computer Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 Compass: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Compass/Mini-Trip Computer Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Compass/Mini-Trip Computer Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6672 Compass: Description and Operation COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer is located in the overhead console. The CMTC consists of a electronic control module with a vacuum fluorescent display (VFD) and function switches. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: Average Fuel Economy (AVG ECO) - Distance To Empty (DTE) - Instantaneous Fuel Economy (ECO) - Elapsed Time (ET) - Trip Odometer (ODO) Compass Mini-Trip Computer (CMTC) Switches and Display The CMTC module in the overhead console has three buttons used to select various functions. The CMTC selector buttons will not operate until the ignition is in the RUN position. When the ignition switch is first turned to the RUN position, the CMTC display: Blanks momentarily - All segments of the VFD will light for one second - Blanks momentarily - Returns to the last mode setting selected before the ignition was last switched OFF. The information needed for the traveler functions is received over the CCD bus from the Body Control Module. If the Compass/Mini-Trip Computer has been replaced, it may be necessary to reset the calibration. SYSTEM OPERATION Setting The Compass The Compass/Mini-Trip Computer module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. See the service procedure. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6673 Compass Magnetic Variance Zones Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the following zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Computer (CMTC) to Compass/Temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation, NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS. Compass Mini-Trip Computer Self Diagnostic Test The Compass Mini-Trip Computer (CMTC) is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a DRB lll scan tool and the proper Body Diagnostic Procedures or by the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP button. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check, the CMTC will display. PASS - FAIL - CCD If any segment of the CMTC fails to light replace the module. If FAIL is displayed, replace the module. If CCD is displayed, check the CCD and Body Control Module (BCM) for proper operation, refer to the appropriate diagnostic test procedures. If the CCD and the BCM are OK, replace the CMTC module. For additional diagnostic information on the CMTC and for identifying CMTC problems, refer to the proper Body Diagnostic Procedures. Compass The CMTC is self calibrating and usually requires no adjustment. The compass will continuously perform a slow calibration to compensate for small magnetic variations common to any automobile. Uncommon magnetic shifts may be caused by items such as magnetic base antennas, which can permanently alter the magnetic field of the vehicle roof panel. If excessive magnetic field continues for 5 minutes, the compass heading will go blank and only the CAL symbol will illuminate. When this occurs, the vehicle roof panel may require demagnetizing. Refer to the demagnetizing procedure. Moderate magnetic shifts may, on very rare occasions, cause the compass heading to display only one or two of the eight possible headings. Although the compass will eventually compensate for this shift, it could take several ignition cycles. The compensation process can be expedited by manually activating the fast calibration routine. Refer to the fast calibrating procedure. This procedure may be performed anytime that the compass appears to be inaccurate. If the calibration data stored in the body control module is not received, the compass will read only NE North-East. The CMTC is self calibrating and requires no adjusting. The word CAL is displayed to show that the compass is in calibration mode. CAL will turn off after the vehicle has gone through three complete circles without stopping, in an area free of magnetic disturbance. If module displays temperature while the compass is blank, turn off ignition and run self diagnostics then demagnetize the vehicle. If problem persists, then demagnetize vehicle. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Self-Check For Compass Mini-Trip (CMTC) Compass: Testing and Inspection Self-Check For Compass Mini-Trip (CMTC) The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a scan tool and the proper Body Control Module Testing and Inspection Procedures or by using the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check the CMTC will display. PASS - FAIL - CCD If any segment of the CMTC fails to light replace the module. If FAIL is displayed replace the module. If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper operation. If the CCD bus and the BCM are OK, replace the CMTC module. Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Mini-Trip Computer (Cmtc) Module Replacement Compass: Service and Repair Compass Mini-Trip Computer (Cmtc) Module Replacement REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body and Frame/Interior Trim/Overhead Console Replacement. Compass Mini-Trip Computer 3. Remove the six screws holding CMTC module to overhead console. 4. Remove CMTC module from console. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Mini-Trip Computer (Cmtc) Module Replacement > Page 6678 Compass: Service and Repair Compass Mini-Trip Computer (Cmtc) Lamp Bulbs REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body and Frame/Interior Trim/Overhead Console Replacement. CMTC Lamp Bulbs 3. Rotate bulb socket counterclockwise one quarter turn. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Mini-Trip Computer (Cmtc) Module Replacement > Page 6679 Compass: Service and Repair Compass Calibration Procedure (Fast Method) When the compass is subjected to excessive magnetic fields, the CMTC automatically enters a fast calibration mode where is tries to compensate for the large magnetic shifts. If the compass is inaccurate, appears to be inaccurate and the CAL is not illuminated the fast calibration mode may be manually entered by using the following procedure. 1. Set the CMTC to Compass/Temperature mode and press the reset button for 10 continuous seconds. Manual activation of the fast calibration is generally not required. 2. Compass variance sets to the default of 8 after the fast calibration is manually activated. 3. Complete the compass variance setting procedure by referring to the Compass Variance Procedure. 4. Drive the vehicle in three 360° turns in an area free from large metal objects. If the CAL symbol remains lit after completing this step, the roof panel may need demagnetizing Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Mini-Trip Computer (Cmtc) Module Replacement > Page 6680 Compass: Service and Repair Compass Calibration Procedure Variance Settings Variance is the difference between magnetic North and geographic North. To adjust the compass variance set the CMTC to Compass/Temperature mode and press RESET buttons for 5 seconds. The symbol VAR and the current variance zone number will be displayed. Press the STEP button to select the proper variance zone. Press the US/Metric button to save the new vanance zone and normal CMTC operation. If the RESET button is held for 10 seconds instead 5 seconds the CMTC will set variance to 8 and enter the fast calibration mode. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6686 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to diagnose the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations Information Center Information Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 Driver/Vehicle Information Display: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 Driver/Vehicle Information Display: Connector Views Connector Pin Identification Message Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Driver/Vehicle Information Display: Electrical Diagrams Information Center Wiring Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Message Center -- Sheet 8w-46-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Message Center -- Sheet 8w-46-3 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Message Center -- Sheet 8w-46-4 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Message Center -- Sheet 8w-46-5 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Message Center -- Sheet 8w-46-6 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 6717 Driver/Vehicle Information Display: Description and Operation The Overhead Console consists of a Compass/Mini-Trip Computer (CMTC), Universal Transmitter and Reading/Dome lamps. The CMTC consists of an electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC displays compass heading, trip computer with traveler messages, and exterior temperature features. For more information on CMTC features, see Instrument Panel/Compass, Outside Temperature Display, and Lighting/Dome Lamp. The Universal Transmitter replaces the hand held remote controls that open the garage door, motorized gates, or home lighting in/outside the home. This device memorizes the activator codes for up to three remote controlled devices. It triggers those devices at the push of a button, located in a unit permanently mounted in your overhead console (if equipped). The transmitter operates off the vehicle's battery and charging system; no batteries are needed. The Universal Transmitter incorporates a Rolling Code technology (random digital code signals from the remote transmitter) within the transmitter module. This is done so as an added security measure. Features of the Universal Transmitter are: ^ Can be used with most other Radio Frequency (RF) activated devices. ^ Individual channels can be trained. ^ Stores transmitter data in permanent memory- retraining is not required even if the battery dies or is disconnected. To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light up while the signal is being transmitted. NOTE: For security reasons, you are able to erase the trained frequencies. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Universal Transmitter Training and Erasing Driver/Vehicle Information Display: Service and Repair Universal Transmitter Training and Erasing Universal Transmitter TRAINING 1. Turn off the engine. 2. Erase the factory test codes by pressing the two outside buttons. Release the buttons when the red light begins to flash (about 20 seconds). 3. Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. The red light on the universal transmitter will begin to flash slowly. 4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as 60 seconds), release both buttons. Your universal transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your hand-held transmitter in case you need to retrain the universal transmitter. ERASING To erase the universal transmitter codes, simply hold down the two outside buttons until the red LED begins to flash. NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 6720 Driver/Vehicle Information Display: Service and Repair Replacement Universal Transmitter REMOVAL The Universal Transmitter is serviced with the transmitter bin door, in the overhead console. Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Open transmitter bin door in rear of overhead console. 3. Gently pull towards rear of vehicle, releasing transmitter bin door. 4. Disconnect harness connector from Universal Transmitter and remove bin door from vehicle. INSTALLATION For installation, reverse the above procedures. The Universal Transmitter will need to be retrained. Refer to SERVICE PROCEDURES. Message Center REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove A-pillar trim panel. 3. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. 4. Disconnect the wire connector from back of message center 5. Remove screws holding message center to instrument panel top cover. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 6721 6. Remove message center from instrument panel top cover. INSTALLATION 1. Place message center in position on top cover. 2. Install screws to hold message center to instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install instrument panel top cover. 5. Install A-pillar trim. Message Center Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. Message Center Lamp Location 3. Locate the lamp in question. 4. Remove lamp and check lamp. If lamp is good test the power supply to the lamp. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > About Diagnostic Procedures Fuel Gauge: Testing and Inspection About Diagnostic Procedures Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS . Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6734 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming Negative Battery Cable WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to diagnose the problem. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation This vehicle does not have a Maintenance Reminder Light option. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR (CHECK ENGINE) LAMP-PCM OUTPUT The PCM supplies the malfunction indicator (check engine) lamp on/off signal to the instrument panel through the CCD Bus. The CCD Bus is a communications port. Various modules use the CCD Bus to exchange information. The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3 seconds as a bulb test. The Malfunction Indicator Lamp (MIL) stays on continuously, when the PCM has entered a Limp-In mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM compensates for the failure of certain components that send incorrect signals. The PCM substitutes for the incorrect signals with inputs from other sensors. If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the MIL. At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger the MIL (Check Engine Lamp) refer to the On-Board Diagnostics Chart. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > About Diagnostic Procedures Odometer: Testing and Inspection About Diagnostic Procedures Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6745 Odometer: Testing and Inspection Odometer Diagnosis Odometer Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6746 Odometer Diagnosis (Part 2 Of 2) When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially. If a segment in the odometer does not illuminate normally, a problem exists in the display. Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > Page 6747 Odometer: Service and Repair REMOVAL 1. Remove instrument cluster. Refer to Instrument Cluster with Mechanical Transmission Range Indicator Replacement. 2. Remove cluster lens. 3. Disconnect wire connector from odometer and transmission range indicator. 4. Remove screws holding odometer and transmission range indicator to cluster shell. 5. Remove odometer and transmission range indicator from cluster. INSTALLATION 1. Install odometer and transmission range indicator and attach to cluster shell. 2. Connect wire connector into odometer and transmission range indicator. 3. Install cluster lens. 4. Install instrument cluster. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 6751 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Gauge Sending Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 6755 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 6756 Oil Pressure Sender: Diagrams Engine Oil Pressure Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations Cigarette Lighter Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations > Page 6765 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations > Page 6766 Cigarette Lighter Relay: Diagrams Power Distribution Center Cigar Lighter/Accessory Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Diagrams Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures Speedometer Head: Testing and Inspection About Diagnostic Procedures Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6778 Speedometer Head: Testing and Inspection Speedometer Diagnosis Speedometer Diagnosis (Part 1 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6779 Speedometer Diagnosis (Part 2 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6780 Speedometer Diagnosis (Part 3 Of 3) Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6781 Speedometer Head: Testing and Inspection Helpful Hints ELECTRONIC PINION FACTOR A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRBIII (R) Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: ^ If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when the vehicle is moving. ^ Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification. Use the following procedures to set the electronic pinion factor using the DRBIII (R) Scan Tool: ^ Select "Transmission" system, then "Miscellaneous" functions, the "Pinion Factor". The DRBIII (R) will display the current tire size. ^ If the tire size is incorrect, depress the Enter key and then select the correct size. ^ Depress the Page Back key to exit the reset procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER-PCM OUTPUT The PCM supplies engine RPM to the instrument panel tachometer through the CCD Bus. The CCD Bus is a communications port. Various modules use the CCD Bus to exchange information. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection > About Diagnostic Procedures Tachometer: Testing and Inspection About Diagnostic Procedures Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6787 Tachometer: Testing and Inspection Tachometer Test Tachometer Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6788 Tachometer Diagnosis (Part 2 Of 2) Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Temperature Gauge: Initial Inspection and Diagnostic Overview Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6793 Temperature Gauge: Component Tests and General Diagnostics Temperature Gauge Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6794 Temperature Gauge Diagnosis (Part 2 Of 2) Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender Unit 60 in.lb Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection Traction Control Indicator Lamp: Testing and Inspection The traction control light is tested by cycling the traction control switch on and off. The traction control switch used on this vehicle is a momentary contact type switch. The test procedure for the traction control light is performed as follows: Press the traction control switch once and the TRAC OFF lamp will illuminate. With the TRAC OFF lamp illuminated, press the traction control switch again and the TRAC OFF lamp will turn off. If the traction control lamp does not function as described in the test above, diagnosis of the traction control switch, lamp, wiring and other related components of the traction control system is required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures Transmission Shift Position Indicator Lamp: Testing and Inspection About Diagnostic Procedures Instrument Cluster DTC Table These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6805 Transmission Shift Position Indicator Lamp: Testing and Inspection Electronic Gear Indicator Display Diagnostic Chart Electronic Gear Indicator Display Diagnosis (Part 1 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6806 Electronic Gear Indicator Display Diagnosis (Part 2 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6807 Electronic Gear Indicator Display Diagnosis (Part 3 Of 3) Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6808 Transmission Shift Position Indicator Lamp: Testing and Inspection Electronic Transmission Range Indicator Segment Test When CHEC-3 is displayed in the odometer window, each segment of the transmission range indicator will illuminate sequentially. If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display board. Conditions Refer to the following tables: Instrument Cluster - Speedometer - Tachometer - Fuel Gauge - Temperature Gauge - Odometer - Electronic Transmission Range Indicator (PRND3L) - Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections. Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > Page 6809 Transmission Shift Position Indicator Lamp: Service and Repair REMOVAL 1. Remove instrument cluster. Refer to Instrument Cluster with Mechanical Transmission Range Indicator Replacement. 2. Remove cluster lens. Refer to Instrument Cluster Lens Replacement. 3. Remove screws holding mechanical transmission range indicator to back of cluster lens. 4. Remove mechanical transmission range indicator from cluster lens. INSTALLATION 1. Position transmission range indicator on cluster lens. 2. Install mechanical range indicator and attaching screws to back of cluster lens. 3. Install cluster lens. 4. Install instrument cluster. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams For a three speed automatic please refer to: Starting and Charging, Starting System, Neutral Safety Switch, See: Sensors and Switches/Sensors and Switches - Starting and Charging/Neutral Safety Switch For a four speed automatic please refer to: Transmission and Drivetrain, Automatic Transmission/Transaxle, Sensors and Switches - A/T, Transmission Position Switch/Sensor, A/T, See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Transmission Position Switch/Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter panel. Tail, Stop, Turn Signal And Back-up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair Brake Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter panel. Tail, Stop, Turn Signal And Back-up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Brake Switch (Typical) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6825 Brake Light Switch: Diagrams Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6826 Brake Light Switch: Description and Operation DESCRIPTION The switch is mounted on the brake pedal mounting bracket under the instrument panel. OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM monitors the state of the dual function stop lamp switch. Refer to the stop lamp switch service and adjustment procedures. BRAKE SWITCH-PCM INPUT When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through control of the idle air control motor. The brake switch is mounted on the brake pedal support bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6827 Brake Light Switch: Testing and Inspection Stop Lamp Wiring 1. Remove the stop lamp switch refer to Stop Switch Replacement. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6828 Brake Light Switch: Adjustments 1. Remove stop lamp switch from its bracket by rotating it approximately 30 in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30 to lock the switch into the bracket. Stop Light Switch Location In Vehicle CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6829 Brake Light Switch: Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Disengage clips holding CHMSL access trim cover to liftgate. 3. Remove trim cover from liftgate. 4. Rotate bulb socket counterclockwise one quarter turn. CHMSL Bulb 5. Pull socket from lamp. 6. Pull bulb from socket. INSTALLATION 1. Insert bulb into socket. 2. Insert socket into lamp. 3. Rotate bulb socket clockwise one quarter turn. 4. Place CHMSL access trim cover in position on liftgate. 5. Engage clips to hold access cover to liftgate. 6. Verify CHMSL operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb Courtesy Lamp Bulb: Service and Repair Front Door Courtesy Lamp Bulb REMOVAL Door Courtesy Lamp Lens 1. Using a small, flat bladed pry tool, pry rear edge of courtesy lamp lens from courtesy lamp. 2. Remove lens from lamp. 3. Squeeze brass lamp bulb contacts together gently. Door Courtesy Lamp Bulb 4. Disengage bulb from lamp contacts. 5. Remove bulb from lamp. INSTALLATION 1. Position bulb to lamp contacts. 2. Engage bulb to lamp contacts. 3. Insert long edge of lens into lamp housing. 4. Press on center of lens to engage remainder of clips. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb > Page 6839 Courtesy Lamp Bulb: Service and Repair Header Reading / Courtesy Lamp Bulb REMOVAL 1. Insert a small, flat bladed pry tool at forward position between reading/courtesy lamp lens and lamp housing. Reading/Courtesy Lamp Lens 2. Pry lamp lens from lamp housing. 3. Insert a small, flat bladed pry tool between lamp light shield and lamp housing at inboard rear corner of light shield. Reading/Courtesy Lamp Light Shield 4. Pry light shield from housing. 5. Carefully press forward lamp bulb contact toward opposite contact and rotate. 6. Remove bulb from lamp bulb contacts. INSTALLATION 1. Carefully press forward lamp bulb contact toward opposite contact and rotate bulb into position. 2. Position bulb to lamp bulb contacts. 3. Release lamp bulb contacts. 4. Insert outer edge of light shield into lamp housing. 5. Rotate light shield upward and snap inboard edge into lamp housing. 6. Position lens switch tab to lamp switch. 7. Press lens pivots to tabs on lamp housing until both pivots are seated. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb > Page 6840 Courtesy Lamp Bulb: Service and Repair Liftgate Courtesy Lamp Bulb REMOVAL 1. Remove liftgate courtesy lamp. 2. Insert a small, flat bladed pry tool between courtesy lamp lens and courtesy lamp body. Liftgate Courtesy Lamp Bulb 3. Carefully depress tabs holding lens to courtesy lamp body. 4. Remove lamp lens from lamp body. 5. Carefully press lamp bulb contact toward opposite contact. 6. Remove bulb from lamp body. INSTALLATION 1. Carefully press lamp bulb contact toward opposite contact. 2. Position bulb to lamp bulb contacts. 3. Position long side of lamp lens to tabs on lamp body. 4. Press on center of lens to engage tabs on opposite side of lamp body. 5. Install liftgate courtesy lamp. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb > Page 6841 Courtesy Lamp Bulb: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb REMOVAL 1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading lamp bulb socket one quarter turn counterclockwise. Reading/Courtesy Lamp 3. Pull socket out of lamp. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens onto lamp lens pivots. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 6845 Courtesy Lamp Relay: Diagrams Junction Block Courtesy Lamp Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair Glove Box Lamp: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Glove Box Lamp And Switch 2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch. 5. Remove glove box lamp and switch. Glove Box Lamp 6. Remove lamp. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Page 6849 REMOVAL 1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument panel. Headlamp Switch 3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle. INSTALLATION 1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Glove Box Lamp And Switch 2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch. 5. Remove glove box lamp and switch. Glove Box Lamp 6. Remove lamp. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair > Page 6853 REMOVAL 1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument panel. Glove Box Lamp And Switch 3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle. INSTALLATION 1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation SYSTEM OPERATION Combination Flasher / Daytime Running Lamps (DRL) Module Junction Block Terminal Pins The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions, and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker, refer to Instrument Panel and Systems. The combination flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of 300 mA., and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground that could draw a maximum of 600 mA. through the multi-function switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6858 Daytime Running Lamp Control Unit: Testing and Inspection Electronic Combination Flasher Circuit Electronic Combination Flasher With DRL Circuit The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/ DRL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6859 Junction Block Terminal Call-Out Junction Block Terminal Call-Out With DRL The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: - Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6860 Combination Flasher Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6861 Combination Flasher Diagnosis (Part 2 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6862 Combination Flasher Diagnosis With DRL (Part 1 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6863 Combination Flasher Diagnosis With DRL (Part 2 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6864 Combination Flasher Diagnosis With DRL (Part 3 Of 3) For diagnostic test procedures, refer to Combination Flasher Diagnosis tables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Rail Lamp Module Bulb Dome Lamp Bulb: Service and Repair Rail Lamp Module Bulb REMOVAL Rail Lamp Module Lens 1. Using a small screw driver, pry stationary end of rail lamp lens from rail lamp module. 2. Remove lens tab from between rail lamp module and rail lamp switch. 3. Remove lens from lamp. Rail Lamp Module Bulb 4. Pull bulb from lamp. INSTALLATION 1. Push bulb into bulb contacts in rail lamp module. 2. Insert tab on lamp lens between rail lamp module and rail lamp switch. 3. Snap lens onto lens pivots on module. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Rail Lamp Module Bulb > Page 6870 Dome Lamp Bulb: Service and Repair Dome Lamp Bulb REMOVAL 1. Insert a small, flat bladed pry tool between dome lamp lens and dome lamp body on left side of dome lamp. Dome Lamp Bulb 2. Disengage left side of dome lamp lens from lamp body. 3. Pull bulb from lamp socket. INSTALLATION 1. Push bulb into lamp socket. 2. Pivot dome lamp lens upward. Verify that lamp lens hook is above the headlining. 3. Engage left side of dome lamp lens to lamp body. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6879 Hazard Warning Flasher: Diagrams Junction Block Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6880 Combination Flasher Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6881 Hazard Warning Flasher: Description and Operation SYSTEM OPERATION Combination Flasher Function The Turn Signal/Hazard Warning Flasher is a module providing turn signal, hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at positions 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker, refer to Instrument Panel and Systems. The combination flasher may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit must be completed to the module. While the combination flasher is idle, there is no current drawn through the module. The device does not become active until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of 300 mA., and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground drawing a maximum of 600 mA. through the multi-function switch. Combination Flasher / Daytime Running Lamps (DRL) Module Junction Block Terminal Pins The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions, and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker, refer to Instrument Panel and Systems. The combination flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of 300 mA., and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground that could draw a maximum of 600 mA. through the multi-function switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6882 Hazard Warning Flasher: Testing and Inspection Electronic Combination Flasher Circuit Electronic Combination Flasher With DRL Circuit The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/ DRL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6883 Junction Block Terminal Call-Out Junction Block Terminal Call-Out With DRL The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: - Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6884 Combination Flasher Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6885 Combination Flasher Diagnosis (Part 2 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6886 Combination Flasher Diagnosis With DRL (Part 1 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6887 Combination Flasher Diagnosis With DRL (Part 2 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6888 Combination Flasher Diagnosis With DRL (Part 3 Of 3) For diagnostic test procedures, refer to Combination Flasher Diagnosis tables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6889 Hazard Warning Flasher: Service and Repair Combination Flasher With/Without DRL Module REMOVAL Battery Negative Cable 1. Disconnect and isolate battery negative cable. 2. Remove lower steering column cover. Refer to Instrument Panel and Systems for Replacement. 3. Remove knee blocker. Refer to Instrument Panel and Systems for Removal and Installation. 4. Pull combination flasher from junction block. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6893 Hazard Warning Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6894 Hazard Warning Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR PROPER AND SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Battery Negative Cable 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. From behind radiator closure panel, disconnect wire connector from back of headlamp bulb base. 3. Rotate headlamp bulb retaining ring counterclockwise. Headlamp Bulb 4. Remove retaining ring from headlamp. 5. Pull headlamp bulb from back of headlamp. INSTALLATION CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. 1. From behind radiator closure panel, insert headlamp bulb into back of headlamp. 2. Engage retaining ring onto headlamp. 3. Rotate headlamp bulb retaining ring clockwise. 4. Connect wire connector into headlamp bulb base. 5. Verify headlamp alignment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Technical Service Bulletins > Recalls for Headlamp Control Module: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: Recalls Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Control Module: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6915 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6916 Headlamp Relay: Diagrams Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6917 Power Distribution Center -- Sheet 8w-10-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch C1 Headlamp Switch C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6921 Headlamp Switch: Testing and Inspection Headlamp Switch Continuity Rheostat Continuity Headlamp Switch Connectors (Switch Side) Using a Digital Multimeter equipped with a diode test, perform the Headlamp Switch Continuity test and the Rheostat Continuity test. Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary. The Chrysler Town and Country is available with optional Automatic Headlamps. For diagnosis, refer to the proper Body Diagnostic Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlight Switch Headlamp Switch: Service and Repair Headlight Switch REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Headlamp Switch 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove screws holding the headlamp switch bezel to cluster bezel. 4. Disconnect the wire connectors from the headlamp switch and wire connector from the power mirror switch. 5. Remove headlamp switch bezel from cluster bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlight Switch > Page 6924 Headlamp Switch: Service and Repair Headlight Switch Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. 3. Disconnect wire connectors. 4. Remove headlamp switch bezel from instrument cluster bezel. Headlamp Switch Lamp 5. Rotate bulb socket counterclockwise one quarter turn. 6. Pull bulb socket from headlamp switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Diagrams High Beam Relay: Diagrams Power Distribution Center High Beam Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Diagrams Low Beam Relay: Diagrams Power Distribution Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Diagrams > Page 6931 Low Beam Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6936 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6937 Horn Relay: Diagrams Power Distribution Center Horn Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6938 Horn Relay: Testing and Inspection 1. Remove horn relay. Horn Relay 2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance. If resistance not OK, replace relay 3. Test for continuity between ground and terminal 85 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary, refer to Passive Restraints for Driver's Airbag Module Replacement. 4. Using voltmeter, test voltage at: a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM. c. If incorrect voltage repair as necessary. 5. Insert a jumper wire between terminal 30 and 87 of the power distribution center. a. If horn sounds replace relay b. If the horn does not sound, install horn relay and refer to Horn Test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Speed Control Switches Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6942 Horn Switch: Service and Repair REMOVAL AND INSTALLATION The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately. Refer to Passive Restraints for Driver Airbag Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Service and Repair Key Cylinder Lamp: Service and Repair Ignition Halo Lamp Bulb REMOVAL 1. Remove steering column trim covers. Ignition Halo Lamp Bulb 2. Rotate bulb socket counterclockwise one quarter turn. 3. Pull bulb socket from halo lamp. INSTALLATION 1. Push bulb socket into halo lamp. 2. Rotate bulb socket clockwise one quarter turn. 3. Install steering column trim covers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL 1. Remove screws attaching license plate lamp lens to liftgate. 2. Remove license plate lamp lens from lamp. 3. Rotate lamp socket counterclockwise one quarter turn. License Plate Lamp Bulb 4. Pull socket from lens. 5. Pull bulb from socket. INSTALLATION 1. Install bulb into socket. 2. Insert socket into lens. 3. Rotate lamp socket clockwise one quarter turn. 4. Place license plate lamp lens in position in lamp. 5. Install screws attaching license plate lamp lens. 6. Verify license plate lamp operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Header Reading/Courtesy Lamp Bulb Map Light Bulb: Service and Repair Header Reading/Courtesy Lamp Bulb REMOVAL 1. Insert a small, flat bladed pry tool at forward position between reading/courtesy lamp lens and lamp housing. Reading/Courtesy Lamp Lens 2. Pry lamp lens from lamp housing. 3. Insert a small, flat bladed pry tool between lamp light shield and lamp housing at inboard rear corner of light shield. Reading/Courtesy Lamp Light Shield 4. Pry light shield from housing. 5. Carefully press forward lamp bulb contact toward opposite contact and rotate. 6. Remove bulb from lamp bulb contacts. INSTALLATION 1. Carefully press forward lamp bulb contact toward opposite contact and rotate bulb into position. 2. Position bulb to lamp bulb contacts. 3. Release lamp bulb contacts. 4. Insert outer edge of light shield into lamp housing. 5. Rotate light shield upward and snap inboard edge into lamp housing. 6. Position lens switch tab to lamp switch. 7. Press lens pivots to tabs on lamp housing until both pivots are seated. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Header Reading/Courtesy Lamp Bulb > Page 6955 Map Light Bulb: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb REMOVAL 1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading lamp bulb socket one quarter turn counterclockwise. Reading/Courtesy Lamp 3. Pull socket out of lamp. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens onto lamp lens pivots. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 6960 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 6961 Parking Lamp Relay: Diagrams Power Distribution Center Park Lamp Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 6966 Courtesy Lamp Relay: Diagrams Junction Block Courtesy Lamp Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation SYSTEM OPERATION Combination Flasher / Daytime Running Lamps (DRL) Module Junction Block Terminal Pins The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions, and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker, refer to Instrument Panel and Systems. The combination flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of 300 mA., and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground that could draw a maximum of 600 mA. through the multi-function switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6970 Daytime Running Lamp Control Unit: Testing and Inspection Electronic Combination Flasher Circuit Electronic Combination Flasher With DRL Circuit The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/ DRL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6971 Junction Block Terminal Call-Out Junction Block Terminal Call-Out With DRL The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: - Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6972 Combination Flasher Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6973 Combination Flasher Diagnosis (Part 2 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6974 Combination Flasher Diagnosis With DRL (Part 1 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6975 Combination Flasher Diagnosis With DRL (Part 2 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 6976 Combination Flasher Diagnosis With DRL (Part 3 Of 3) For diagnostic test procedures, refer to Combination Flasher Diagnosis tables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Technical Service Bulletins > Recalls for Headlamp Control Module: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: Recalls Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Control Module: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module Defect Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL" as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles do not comply with requirements of FMVSS No. 108. All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters. Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6996 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6997 Headlamp Relay: Diagrams Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6998 Power Distribution Center -- Sheet 8w-10-6 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Diagrams High Beam Relay: Diagrams Power Distribution Center High Beam Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7005 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7006 Horn Relay: Diagrams Power Distribution Center Horn Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7007 Horn Relay: Testing and Inspection 1. Remove horn relay. Horn Relay 2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance. If resistance not OK, replace relay 3. Test for continuity between ground and terminal 85 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary, refer to Passive Restraints for Driver's Airbag Module Replacement. 4. Using voltmeter, test voltage at: a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM. c. If incorrect voltage repair as necessary. 5. Insert a jumper wire between terminal 30 and 87 of the power distribution center. a. If horn sounds replace relay b. If the horn does not sound, install horn relay and refer to Horn Test. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams Low Beam Relay: Diagrams Power Distribution Center Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams > Page 7011 Low Beam Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 7015 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 7016 Parking Lamp Relay: Diagrams Power Distribution Center Park Lamp Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams For a three speed automatic please refer to: Starting and Charging, Starting System, Neutral Safety Switch, See: Sensors and Switches/Sensors and Switches - Starting and Charging/Neutral Safety Switch For a four speed automatic please refer to: Transmission and Drivetrain, Automatic Transmission/Transaxle, Sensors and Switches - A/T, Transmission Position Switch/Sensor, A/T, See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Transmission Position Switch/Sensor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Brake Switch (Typical) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7024 Brake Light Switch: Diagrams Connector Pin Identification Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7025 Brake Light Switch: Description and Operation DESCRIPTION The switch is mounted on the brake pedal mounting bracket under the instrument panel. OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM monitors the state of the dual function stop lamp switch. Refer to the stop lamp switch service and adjustment procedures. BRAKE SWITCH-PCM INPUT When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through control of the idle air control motor. The brake switch is mounted on the brake pedal support bracket. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7026 Brake Light Switch: Testing and Inspection Stop Lamp Wiring 1. Remove the stop lamp switch refer to Stop Switch Replacement. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7027 Brake Light Switch: Adjustments 1. Remove stop lamp switch from its bracket by rotating it approximately 30 in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30 to lock the switch into the bracket. Stop Light Switch Location In Vehicle CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7028 Brake Light Switch: Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7037 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7038 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7039 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7040 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7041 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7042 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7048 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7049 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7050 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7051 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7052 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7053 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Glove Box Lamp And Switch 2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch. 5. Remove glove box lamp and switch. Glove Box Lamp 6. Remove lamp. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 7057 REMOVAL 1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument panel. Glove Box Lamp And Switch 3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle. INSTALLATION 1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7061 Hazard Warning Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7062 Hazard Warning Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR PROPER AND SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Battery Negative Cable 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch C1 Headlamp Switch C2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 7066 Headlamp Switch: Testing and Inspection Headlamp Switch Continuity Rheostat Continuity Headlamp Switch Connectors (Switch Side) Using a Digital Multimeter equipped with a diode test, perform the Headlamp Switch Continuity test and the Rheostat Continuity test. Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary. The Chrysler Town and Country is available with optional Automatic Headlamps. For diagnosis, refer to the proper Body Diagnostic Procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch Headlamp Switch: Service and Repair Headlight Switch REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. Headlamp Switch 2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove screws holding the headlamp switch bezel to cluster bezel. 4. Disconnect the wire connectors from the headlamp switch and wire connector from the power mirror switch. 5. Remove headlamp switch bezel from cluster bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch > Page 7069 Headlamp Switch: Service and Repair Headlight Switch Lamp REMOVAL Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. 3. Disconnect wire connectors. 4. Remove headlamp switch bezel from instrument cluster bezel. Headlamp Switch Lamp 5. Rotate bulb socket counterclockwise one quarter turn. 6. Pull bulb socket from headlamp switch. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Speed Control Switches Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7073 Horn Switch: Service and Repair REMOVAL AND INSTALLATION The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately. Refer to Passive Restraints for Driver Airbag Module Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7077 Turn Signal Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7078 Turn Signal Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter panel. Tail, Stop, Turn Signal And Back-up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7092 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7093 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7094 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7095 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7096 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7097 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7103 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7104 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7105 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7106 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7107 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7108 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Combination Flasher Location Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Flasher: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 Turn Signal Flasher: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 Turn Signal Flasher: Connector Views Junction Block Terminal Pins Junction Block Terminal Call-Out With DRL Junction Block Terminal Pins Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 Junction Block Terminal Call-Out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 Turn Signal Flasher: Electrical Diagrams Electronic Combination Flasher With DRL Circuit Junction Block Terminal Call-Out With DRL Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 Electronic Combination Flasher Circuit Junction Block Terminal Call-Out Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) Turn Signal Flasher: Description and Operation Combination Flasher -- With Daytime Running Lamps (DRL) Combination Flasher Location SYSTEM OPERATION The turn signals are actuated with a lever on the left side of the steering column just ahead of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: Combination flasher - Multi-function switch - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn signal ON. FLASHER MODULE DESCRIPTION The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4, where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the flasher, remove the lower steering column cover and knee blocker. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7138 Junction Block Terminal Pins FLASHER MODULE OPERATION The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions, and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions 3 and 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker. The combination flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of 300 mA, and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground that could draw a maximum of 600 mA. through the multi-function switch. Electronic Combination Flasher With DRL Circuit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7139 Junction Block Terminal Call-Out With DRL CIRCUIT OPERATION The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/DRL. The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7140 Turn Signal Flasher: Description and Operation Combination Flasher -- Without Daytime Running Lamps (DRL) Combination Flasher Location SYSTEM OPERATION The turn signals are actuated with a lever on the left side of the steering column just ahead of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: Combination flasher - Multi-function switch - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn signal ON. FLASHER MODULE DESCRIPTION The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4, where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the flasher, remove the lower steering column cover and knee blocker. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7141 Junction Block Terminal Pins FLASHER MODULE OPERATION The Turn Signal/Hazard Warning Flasher is a module providing turn signal, hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker. The combination flasher may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit must be completed to the module. While the combination flasher is idle, there is no current drawn through the module. The device does not become active until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of 300 mA and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground drawing a maximum of 600 mA through the multi-function switch. Electronic Combination Flasher Circuit Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7142 Junction Block Terminal Call-Out CIRCUIT OPERATION The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/DRL. The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7143 Turn Signal Flasher: Description and Operation Combination Flasher Operation SYSTEM OPERATION The turn signals are actuated with a lever on the left side of the steering column just ahead of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: Combination flasher - Multi-function switch - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn signal ON. Circuit Operation The turn signal and hazard flasher system used in this vehicle is controlled by the combination flasher located in the junction block. On vehicles built for sale in Canada the Daytime Running Lamp (DRL) module is part of the combination flasher. Power for the combination flasher is supplied from two sources. One is a direct battery feed on circuit L9. This circuit is HOT at all times and protected by a 20 Amp fuse located in cavity 19 of the Power Distribution Center (PDC). The other power source is a fuse battery feed from the ignition switch on circuit F20. This circuit is HOT in the RUN position only and connects from the ignition switch to the combination flasher. Power for the F20 circuit is supplied on circuit A22/A2. This circuit originates at the PDC and is protected by a 40 Amp fuse located in cavity 2. LEFT TURN SIGNALS Circuit Operation When the operator selects the left turn signal, circuit L305 is connected to the Z1 ground circuit through the turn signal switch. The combination flasher senses the position of the switch and supplies power to the L61 and L63 circuits. Circuit L61 connects from the combination flasher to the left front turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the left cowl panel. Circuit L63 connects from the combination flasher to the left rear turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to the indicator lamp in the message center. RIGHT TURN SIGNALS Circuit Operation When the operator selects the right turn signal circuit L302 is connected to the Z1 ground circuit through the turn signal switch. The combination flasher senses the position of the switch and supplies power to the L60 and L62 circuits. Circuit L60 connects from the combination flasher to the right front turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the right cowl panel. Circuit L62 connects from the combination flasher to the right rear turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to the indicator lamp in the message center. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7144 Turn Signal Flasher: Testing and Inspection Electronic Combination Flasher Circuit Electronic Combination Flasher With DRL Circuit The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/ DRL. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7145 Junction Block Terminal Call-Out Junction Block Terminal Call-Out With DRL The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: - Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7146 Combination Flasher Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7147 Combination Flasher Diagnosis (Part 2 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7148 Combination Flasher Diagnosis With DRL (Part 1 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7149 Combination Flasher Diagnosis With DRL (Part 2 Of 3) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7150 Combination Flasher Diagnosis With DRL (Part 3 Of 3) For diagnostic test procedures, refer to Combination Flasher Diagnosis tables. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7151 Turn Signal Flasher: Service and Repair Combination Flasher With/Without DRL Module REMOVAL Battery Negative Cable 1. Disconnect and isolate battery negative cable. 2. Remove lower steering column cover. Refer to Instrument Panel and Systems for Replacement. 3. Remove knee blocker. Refer to Instrument Panel and Systems for Removal and Installation. 4. Pull combination flasher from junction block. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Testing and Inspection Turn Signal Indicator: Testing and Inspection BCM Controlled Components Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter panel. Tail, Stop, Turn Signal And Back-up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7162 Turn Signal Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7163 Turn Signal Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7169 Heated Glass Element Relay: Diagrams Junction Block Rear Window Defogger Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation SYSTEM OPERATION HVAC Control Panel/Rear Window Defogger Switch The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when the switch is activated. The switch energizes the timing circuit and activates the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Junction Block -- Sheet 8w-12-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7177 Heated Glass Element Relay: Diagrams Junction Block Rear Window Defogger Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation SYSTEM OPERATION HVAC Control Panel/Rear Window Defogger Switch The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when the switch is activated. The switch energizes the timing circuit and activates the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection 1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or passenger side. Refer to Power Window Switch and Bezel Assembly Replacement. Power Window Master Switch Connector 2. Using an ohmmeter, Test driver door switch for continuity as described. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 3. Test passenger door switch for continuity as described. 4. If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down relay senses an amperage spike (motor pushing against down stop) in the feed circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike will cause the switch to disconnect after approximately 11 seconds. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 7185 Power Window Switch: Service and Repair Window Switch and Bezel Replacement The Power Window Switch is integral to the bezel. If service to the switch is required, the complete bezel must be replaced. The Owe Door Lock Switch is serviced separately and must be transferred to the new bezel. REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Open door, remove screw cover near inside door release handle. 3. Remove two screws to Power Window Switch and Bezel Assembly One under the screw cover removed in previous step and one to the rear of the front door vent opening. 4. Pull out and up on bezel to release from door trim panel. 5. Disconnect two switch connectors. 6. Remove two door lock switch retaining screws and remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN AREA WHERE THEY CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE. REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel and sound pad. 3. Tape the window in its existing position to remove its weight from the regulator system. 4. Cut and remove the tie wrap at the window motor. Its no longer required. 5. Disconnect window motor wire connector from door harness. 6. Remove screws and nuts holding window motor to the inner panel. 7. Remove the motor from the door inner panel, let it hang from the cables. 8. With the cables still attached to the failed motor, Install the replacement motor to the door inner panel. Tighten down the screws and nuts to 3.4 to 4.5 Nm (30 to 40 in. lbs.) of torque. 9. Separate the failed motor from regulator by: - Removing the drum cover plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 7191 Power Window Motor Removal - Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously. CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the cables unwind. INSTALLATION 1. Install the cable guide and drum into the replacement motor. CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor shaft by a slight rotation,then, the glass should be lowered a small amount approximately 1 to 2 inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance of a second person. 2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the wiring harness to the window motor connector. 4. Remove the tape holding the window in place and test window operation. 5. Re-assemble remaining parts in reverse order as above. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection 1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or passenger side. Refer to Power Window Switch and Bezel Assembly Replacement. Power Window Master Switch Connector 2. Using an ohmmeter, Test driver door switch for continuity as described. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 3. Test passenger door switch for continuity as described. 4. If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down relay senses an amperage spike (motor pushing against down stop) in the feed circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike will cause the switch to disconnect after approximately 11 seconds. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 7195 Power Window Switch: Service and Repair Window Switch and Bezel Replacement The Power Window Switch is integral to the bezel. If service to the switch is required, the complete bezel must be replaced. The Owe Door Lock Switch is serviced separately and must be transferred to the new bezel. REMOVAL Negative Battery Cable 1. Disconnect and isolate the battery negative cable. 2. Open door, remove screw cover near inside door release handle. 3. Remove two screws to Power Window Switch and Bezel Assembly One under the screw cover removed in previous step and one to the rear of the front door vent opening. 4. Pull out and up on bezel to release from door trim panel. 5. Disconnect two switch connectors. 6. Remove two door lock switch retaining screws and remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator Window Regulator: Service and Repair Front Door Window Regulator FRONT DOOR WINDOW REGULATOR REMOVAL 1. Remove door trim panel and sound shield. 2. Remove door glass retaining clips and allow glass to rest on bottom of door. 3. Disconnect wire connector from power window motor, if equipped. 4. Loosen screws attaching front and rear window guide rails to inner door panel. 5. Remove screw heads on guide rails from key hole slots in inner door panel. 6. Loosen screws attaching regulator to inner door panel. 7. Remove regulator from inner door panel. Front Door Power Window Regulator 8. Extract rear guide rail through inner door panel rear access hole. 9. Extract front guide rail through front access hole. INSTALLATION 1. Insert front guide rail through front access hole. 2. Insert rear guide rail through rear access hole. 3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5. Tighten screws to attach front and rear guide rails to inner door panel. 6. Connect wire connector into power window motor, if equipped. 7. Install door glass. 8. Verify door glass alignment and operation. 9. Install sound shield and door trim panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator > Page 7200 Window Regulator: Service and Repair Power Window Regulator Replacement REMOVAL 1. Remove door trim panel and water shield. 2. Remove door glass retaining clips and allow glass to rest on bottom of door. 3. If equipped, disengage wire connector from power window motor. Front Door Glass Window Lift Guides 4. Loosen screws holding front and rear window lift guides to inner door panel. 5. Separate screw heads on lift guides from key hole slots in inner door panel. 6. Loosen screws holding regulator to inner door panel. 7. Remove regulator from inner door panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator > Page 7201 Front Door Window Regulator 8. Extract rear lift guide through inner door panel access hole. 9. Extract front lift guide through access hole. INSTALLATION 1. Insert front lift guide through access hole. Front Door Window Regulator 2. Insert rear lift guide through access hole. 3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5. Tighten screws to hold regulator to inner door panel. 6. Place screw heads on lift guides in position through key hole slots in inner door panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator > Page 7202 Front Door Glass Window Lift Guides 7. Tighten screws to hold front and rear window lift guides to inner door panel. 8. If equipped, engage wire connector into power window motor. 9. Install door glass. 10. Verify door glass alignment and operation. 11. Install water shield and door trim panel. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Service and Repair Window Seal: Service and Repair Rear Glass Rubber Grommet REMOVAL 1. Remove rear window wiper motor. Refer to Rear Window Wiper Motor Replacement. 2. Peel wiper pivot seal grommet from rear glass. Rear Glass Rubber Grommet 3. Remove grommets from vehicle. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Front Windshield Wiper Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7211 Wiper Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7215 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7216 Wiper Relay: Diagrams Power Distribution Center Wiper High/Low Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7217 Wiper On/Off Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Fig.1 Wiper/Washer Switch Pin Call Out Windshield Wiper and Washer / Multi-function Switch Test 2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper and Washer / Multi-function Switch Test table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 7225 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Turn Signal and Flashers, for Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch Wiper Switch: Testing and Inspection Failed Park Switch If the wiper park switch has failed the windshield wipers will operate as follows: SWITCH OFF Wipers stop in current location regardless of the park signal. INTERMITTENT MODE - Wipers operate at low speed for one or more extra wipes or continuously. LOW SPEED - Wipers operate at low speed. HIGH SPEED - Wipers operate at high speed. PULSE WIPE - Wipers will not operate. WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate only while wash button is depressed with switch in OFF mode, wipers stop in mid-cycle when button is released. Wiper System Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 7231 Wiper System Diagnosis (Part 2 Of 2) The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit can be tested using the Wiper System Diagnosis table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 7232 Wiper Switch: Testing and Inspection Wiper Switch Test To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Fig.1 Wiper/Washer Switch Pin Call Out Windshield Wiper and Washer / Multi-function Switch Test 2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper and Washer / Multi-function Switch Test table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 7233 Wiper Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Turn Signal and Flashers, for Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Rear Washer Pump Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL Negative Battery Cable 1. Disconnect and isolate the negative battery cable. 2. Hoist and support vehicle on safety stands. 3. Remove right front wheel. 4. Remove front wheelhouse splash shield. Negative Battery Cable 5. Disconnect connectors from the front windshield and rear window washer pumps, the fluid level sensor, and the rear washer hose. 6. If washer bottle has fluid in it place a suitable drain pan under the hose connections. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 7243 Front Washer Hose 7. Disconnect front washer hose at front wiper unit in the engine compartment. The front hose will be removed with the bottle. 8. Allow washer bottle to drain. 9. Remove screws holding washer bottle to front fender support and remove bottle. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Fig.1 Wiper/Washer Switch Pin Call Out Windshield Wiper and Washer / Multi-function Switch Test 2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper and Washer / Multi-function Switch Test table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 7247 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Turn Signal and Flashers, for Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments 1. Verify wiper blade element condition and wiper arm spring tension. Run wipers in low speed mode while applying water to the windshield. Observe the wiper blade that is chattering or skipping across the windshield. If the wiper element is not rolling over when the wiper direction reverses, align the wiper arm. The extension bar portion of the wiper arm must be twisted in the proper direction to allow the wiper element to roll over when the direction reverses. 2. Place two small adjustable wrenches placed 50 mm (2 in.) apart on the wiper arm extension rod. 3. Twist the extension rod slightly in the opposite direction that the element is laying on the windshield while holding the wrench closest to the pivot stationary. 4. Repeat step Step 1, and align as necessary until wiper stops chattering and wipes the windshield clear. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Wiper Arm: Service and Repair Wiper Arm CAUTION: The Driver side wiper arm must be parked above the passenger side. Failure to do so will result in damage to the arms, blades, or system. REMOVAL 1. Disengage the clip holding outside end of the wiper arm pivot cover to the wiper arm. 2. Lift the arm cap upward. 3. Remove the nut holding wiper arm to the wiper pivot. Wiper Arm Removal 4. Using a suitable two jaw puller, separate the wiper arm from the wiper pivot. INSTALLATION 1. Verify that the wiper motor and linkage are in the park position. Wiper Arm Adjustment 2. Place the wiper arm in position over the wiper pivot. Refer to Alignment. 3. Install the nut to hold the wiper arm to the wiper pivot. Tighten nut to 35 Nm (26 ft. lbs.). 4. Push the arm cap cover down. 5. Engage clip to the hold outside end of wiper arm pivot cover to the wiper arm. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm > Page 7253 Wiper Arm: Service and Repair Rear Wiper Arm REMOVAL 1. Lift and hold wiper blade away from rear window. 2. Lift lock holding wiper arm to wiper pivot upward. 3. Allow wiper arm to rest against lock. Rear Wiper Arm 4. Pull wiper from pivot. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection Wiper Blade: Service and Repair Cleaning and Inspection Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner. If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to the Wiper Arm Alignment. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7269 Wiper Blade: Service and Repair Rear Wiper Blade REMOVAL 1. Lift wiper blade away from rear window. Rear Wiper Arm 2. Release latch holding blade to wiper arm. 3. Remove blade from wiper arm. INSTALLATION For installation reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7270 Wiper Blade: Service and Repair Rear Wiper Blade Element Replacement REMOVAL AND INSTALLATION Refer to Windshield Wiper Blade Element Replacement. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7271 Wiper Blade: Service and Repair Wiper Blade REMOVAL 1. Lift the wiper arm away from windshield. Windshield Wiper Blade Element 2. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade from the wiper arm. 3. Remove the wiper blade from the wiper arm. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7272 Wiper Blade: Service and Repair Wiper Blade Element REMOVAL Windshield Wiper Blade Element 1. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade from the wiper arm. Windshield Wiper Blade Element 2. Disengage clip holding the wiper element to wiper blade. 3. Pull the element from the claws on the wiper blade. INSTALLATION Wiper Blade And Element 1. Insert the element vertebra into claw at the open end of the wiper blade and through each claw location along the blade. 2. Engage clip to hold wiper element to wiper blade. 3. Test wiper effectiveness using washer mode and align if necessary. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Front Windshield Wiper Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7276 Wiper Module Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Rear Wiper Motor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7280 Rear Wiper Motor Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Rear Wiper Motor Replacement Wiper Motor: Service and Repair Rear Wiper Motor Replacement REMOVAL Negative Battery Cable 1. Disconnect and isolate the negative battery cable. 2. Remove rear wiper arm. Refer to Rear Wiper Arm Replacement. 3. Open liftgate. 4. Remove liftgate trim panel. 5. Disconnect wire connector from rear wiper motor. Rear Window Wiper Motor 6. Remove screws holding rear wiper motor to liftgate. 7. Remove wiper motor from liftgate. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Rear Wiper Motor Replacement > Page 7283 Wiper Motor: Service and Repair Replacement REMOVAL 1. Remove wiper unit from vehicle. Refer to Wiper Unit Replacement. 2. Remove wiper linkage and motor mount plate from wiper unit. Wiper Motor Connector 3. Disconnect wire connectors from back of wiper motor. 4. Remove wiper linkage from motor crank. Do NOT remove crank from motor. Wiper Motor Crank Wiper Motor 5. Remove bolts holding wiper motor to mount plate and remove motor. INSTALLATION 1. Place wiper unit on a suitable work surface. 2. Place wiper motor in position on mount plate. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Rear Wiper Motor Replacement > Page 7284 3. Install bolts to hold wiper motor to mount plate. 4. Install wiper linkage and motor mount plate into wiper unit. 5. Connect wire connectors to wiper motor. Wiper Unit Wire Connector 6. Place the wiper unit into engine compartment and connect wiper unit wire connector to engine wire harness. 7. Operate wiper motor and verify that the wiper motor parks when wiper switch is turned OFF. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove the windshield wiper unit from vehicle. Refer to Wiper Unit Replacement. 2. Place the wiper unit on a suitable work surface. 3. Remove nuts holding the cowl cover brackets to the wiper unit. 4. Remove cowl cover brackets from the wiper unit. Wiper Linkage 5. Remove nuts holding linkage and motor mount plate to the wiper unit. 6. Remove the wiper linkage from the wiper unit. Wiper Motor Connector 7. Disconnect the wire connectors from back of the wiper motor. INSTALLATION For installation, reverse the above procedure. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Battery Negative Cable Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7291 Power Distribution Center -- Sheet 8w-10-2 Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7292 Wiper Relay: Diagrams Power Distribution Center Wiper High/Low Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7293 Wiper On/Off Relay Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi-Function Switch Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch Wiper Switch: Testing and Inspection Failed Park Switch If the wiper park switch has failed the windshield wipers will operate as follows: SWITCH OFF Wipers stop in current location regardless of the park signal. INTERMITTENT MODE - Wipers operate at low speed for one or more extra wipes or continuously. LOW SPEED - Wipers operate at low speed. HIGH SPEED - Wipers operate at high speed. PULSE WIPE - Wipers will not operate. WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate only while wash button is depressed with switch in OFF mode, wipers stop in mid-cycle when button is released. Wiper System Diagnosis (Part 1 Of 2) Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 7299 Wiper System Diagnosis (Part 2 Of 2) The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit can be tested using the Wiper System Diagnosis table. Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 7300 Wiper Switch: Testing and Inspection Wiper Switch Test To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Fig.1 Wiper/Washer Switch Pin Call Out Windshield Wiper and Washer / Multi-function Switch Test 2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper and Washer / Multi-function Switch Test table.