Dodge Caravan 1995 V6 3.3L Workshop Manual

dodge :: Dodge Truck Caravan V6-201 3.3L (1995)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations

Body Control Module System

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module

Keyless Entry Module: Service and RepairProgramming Module

PROGRAMMING RKE MODULE

The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fobtransmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to programthe BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm

(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the

RKE module is set to receive the new VAC.

(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE

module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s).

(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob.

NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, thememory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.

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Keyless Entry Module: Service and RepairRemote Keyless Entry Module Replacement

REMOVAL

(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.

INSTALLATION

Reverse the preceding operation.

> Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations

Door Lock Relay: Locations

> Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 15

Caravan V6-201 3.3L (1995)

The Power Door Lock and Power Door Unlock relays are located in the , which is located behind the instrument panel near the center.micro-relay block

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations

Body Control Module System

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 19

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Module

Keyless Entry Module: Service and RepairProgramming Module

PROGRAMMING RKE MODULE

The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fobtransmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to programthe BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm

(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the

RKE module is set to receive the new VAC.

(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE

module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s).

(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob.

NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, thememory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 22

Keyless Entry Module: Service and RepairRemote Keyless Entry Module Replacement

REMOVAL

(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.

INSTALLATION

Reverse the preceding operation.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Service and Repair

ABS Main Relay: Service and Repair

1. Disconnect battery ground cable.2. Disconnect wiring harness electrical connectors from relays, then remove screw securing relay assembly to left front inner fender.3. Reverse procedure to install.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams

Electronic Brake Control Module: Diagrams

ABS Module Connector

To view sheets referred to in these Diagrams, see NOTE: Diagram Information and Instructions/Complete Body and Chassis Diagrams

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 30

Electronic Brake Control Module: Description and Operation

(CAB)

The Controller Anti-Lock Brake is located on the front lefthand side of the engine compartment. The CAB uses the information from the wheelspeed sensors to control the anti-lock brake system function. The CAB also monitors ABS operation and detects system faults.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 31

Electronic Brake Control Module: Service and Repair

(CAB)

Do not twist connector.

1. With ignition switch in Off position, disconnect both battery cables and remove battery, then remove battery tray from vehicle.2. Remove Controller Anti-lock Brake from battery tray support bracket.3. Loosen bolt securing 60-way connector to CAB, then disconnect connector from CAB by pulling straight out. 4. Remove CAB with its mounting bracket from vehicle.5. Reverse procedure to install, noting the following:

60

a. Ensure ignition switch is still in Off position before connecting -way connector to CAB.b. connector bolt to inch lbs. and CAB assembly mounting bolt to inch lbs.Torque 38 14

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations

Radiator Fan Relay: Locations

Radiator Fan Relay is located in the Power Distribution Center.

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Caravan V6-201 3.3L (1995)

Power Distribution Center

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Caravan V6-201 3.3L (1995)

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions

Radiator Fan Relay: Diagram Information and Instructions

Circuit Function

Circuit Identification

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 theCircuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models.

Circuit Information

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Diagram Information and Instructions > Page 40

Caravan V6-201 3.3L (1995)

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

Connector Identification

Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placednext to the arrows to indicate the connector number.

For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and providesterminal numbering, circuit identification, wire colors, and functions.

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Diagram Information and Instructions > Page 41

Caravan V6-201 3.3L (1995)

All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector LocationsIndex, which uses the connector identification number from the wiring diagrams to provide a figure number reference.

Fasteners

Shock Tower To Spring Minimum Clearance Area

CAUTION:

NO

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 ofan original plastic clip. Also, holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into thestrut 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 thespring. 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.

Splice Location Symbol Identification

Wiring Splice Examples

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Diagram Information and Instructions > Page 42

Caravan V6-201 3.3L (1995)

Wire Color Code Chart

Splice locations

are indicated in the diagrams by a diamond with a splice circuit code within it. If there is more than one splice per circuit a small boxwill be connected to it with the splice number in it.

To locate a splice in the wiring harness determine the splice number from the wiring diagrams, then refer to the splice location index. This section showsthe general location of the splice in the harness.

The wiring diagrams also indicate what harness the splice is located in. To identify the harness an abbreviated call out is placed next to the main splice.

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Caravan V6-201 3.3L (1995)

Symbol Identification

How to Find System & Component Diagrams

Group Index

When trying to find the diagram for a specific component or system, use the information or the under Alphabetic Index to Wiring Diagrams Electrical

Group Index Diagrams By Sheet Number

Whenever a reference exists to another sheet or figure, find the corresponding diagram using the , , or . The reference number for the subsequent diagram will match a listed group shown.Diagrams By Figure Number

Fusible Link Color Code

Fusible Link Chart

Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are colorcoded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification.

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Diagram Information and Instructions > Page 44

Caravan V6-201 3.3L (1995)

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Diagram Information and Instructions > Page 45

Caravan V6-201 3.3L (1995)

Fuse Block Identification

Relay Bank Identification

Symbol and Fuse Identification

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Diagram Information and Instructions > Page 46

Caravan V6-201 3.3L (1995)

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Caravan V6-201 3.3L (1995)

Symbol Identification

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Diagram Information and Instructions > Page 48

Caravan V6-201 3.3L (1995)

Fuse Block

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 ratingother than indicated may result in an electrical overload. If a proper rated fuse continues to blow, it indicates a problem that should be corrected.

Wire Color Codes

Wire Color Code Chart

Wire Color Code Identification

Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shownas a two letter code which can be identified by referring to the Wire Color Code Chart.

Connector and Terminal Replacement

six inches

1/2 inch

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 of tape from the harness.4. Stagger cut all wires on the harness side at intervals.5. Remove of insulation from each wire on the harness side. 1 inch

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Caravan V6-201 3.3L (1995)

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.

1 inch

7. Remove 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).

ends of the tubing.

1-1/2 inches 2 inches

14. Repeat steps 8 through 13 for each wire.15. Re-tape the wire harness starting behind the connector and past the repair.16. Re-connect the repaired connector.17. Connect the battery and test all affected systems.

Connector Replacement

1. Disconnect the battery.2. Disconnect the connector (that is to be repaired) from its mating half/component.

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Caravan V6-201 3.3L (1995)

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. 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 bothDo not use acid core solder.

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 . Pull on the wire to remove the6680

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.

Diode Replacement

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Caravan V6-201 3.3L (1995)

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.

Do not use acid core solder.

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. 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.

Fusible Link Replacement

CAUTION:

Do not replace blown fusible links with a standard wire. Only use fusible type wire with hypalon insulation or damage to the electricalsystem could occur. Also make sure correct gauge of wiring is used. Refer to the wiring diagrams for proper gauge and color.

When a fusible link blows it is important to find out what the problem is. They are placed in the electrical system for protection against shorts to ground.Which can be caused by a component failure or various wiring failures. Do not just replace the fusible link to correct the problem.

When diagnosing a faulty fusible link it is important to check the wire carefully. In some instances the link may be blown and it will not show throughthe insulation, the wire should be checked over its entire length for internal breaks.

one inch

1. Disconnect battery negative cable.2. Cut out the blown portion of the fusible link.3. Strip of insulation from each end of the existing fusible link.4. Place a piece of heat shrink tubing over one side of the fusible link. Make sure the tubing will be long enough to cover and seal the entire repair
area.

two inches

5. Cut a replacement piece of fusible link longer than the piece removed.6. Remove of insulation from each end of the replacement fusible link.one inch

Wire Repair

7. Spread the strands of wire apart on each of the exposed wires (Example 1).8. Push the two ends of the wire together until the strands of wire are close to the insulation (Example 2).9. Twist the wires together (Example 3).

Do not use acid core type solder

10. Solder the wires together using rosin core type solder only. .11. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both

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Caravan V6-201 3.3L (1995)

ends of the tubing.

12. Secure the fusible link to the existing ones to prevent chafing or damage to the insulation.13. Connect battery and test all 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.

Terminal Removal

Terminal Removal Using Special Tool

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Caravan V6-201 3.3L (1995)

4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit . Pull on the wire to remove the6680

terminal from the connector.

6 inches

1 inch

1 inch

5. Cut the wire from the back of the connector.6. Remove 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 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

Do not use acid core solder.

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. 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.

1-1/2 inches 2 inches

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 behind the connector and past the repair.18. Connect the battery and test all affected systems.

Terminal/Connector Repair-Molex Connectors

1. Disconnect the battery.2. Disconnect the connector from its mating half/component.

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Caravan V6-201 3.3L (1995)

Molex Connector Repair

3. Insert the terminal releasing special tool into the terminal end of the connector.6742

Using Special Tool 6742

6742

4. Using special tool , 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

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 securelyin place to prevent damage to the insulation.

1. Disconnect the battery negative cable.

2. Remove of insulation from each end of the wire.1 inch

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Caravan V6-201 3.3L (1995)

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.

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Radiator Fan Relay: Diagnostic Aids

Voltage Check
Foreword

A circuit consists of the power supply, switch, relay, load, ground, etc. There are various methods to check a circuit including an overall check,voltage check, short circuit check and continuity check.

Voltage Check

Voltage Check

1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire.2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter
should indicate a voltage.

3. Then, connect the test light or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage.
When the switch is turned on in this state, the test light should come on, or the voltmeter should indicate a voltage, with motor starting to run.

4. The circuit illustrated here is normal but if there is any problem such as the motor failing to run, check voltages beginning at the connector nearest
to the motor until the faulty part is identified.

Continuity Check
Foreword

A circuit consists of the power supply, switch, relay, load, ground, etc. There are various methods to check a circuit including an overall check,voltage check, short circuit check and continuity check.

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Caravan V6-201 3.3L (1995)

Continuity Check

Continuity Check

a. When the switch is in the OFF position, the self power test light should come on or the ohmmeter should read only when the terminals 10 Ohm

and 2 are interconnected.

b. When the switch is in the ON position, the self power test light should come on or the ohmmeter should read only when the terminals 3 and0 Ohm

4 are interconnected.

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 about six to eight inches apart and watch the voltmeter/test lamp.

4. If the voltmeter registers voltage or the test lamp 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 fused 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 A Voltage Drop

Testing For Voltage Drop

1 Connect the positive lead of the voltmeter 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.

3. Operate the item.

4. The voltmeter will show the difference in voltage between the two points.

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Caravan V6-201 3.3L (1995)

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 aproblem. 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 Problemssection.

Testing For Voltage

Testing For Voltage

1. Connect the ground lead of a voltmeter to a known good ground.2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the
appropriate test procedure.

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Caravan V6-201 3.3L (1995)

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

6 to 8 Inches

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 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.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.

- - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit.Jumper Wire

WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERYFEED 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 tothe 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 or greater impedance.10 megohm

- Ohmmeter

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Diagram Information and Instructions > Page 60

Caravan V6-201 3.3L (1995)

- This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean goodcontinuity or a shorted circuit.

CAUTION:

10 megohm

Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter witha or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicleelectrical system can cause damage to the equipment and provide false readings.

Probing Tool

- Probing Tools 6807

- These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package and insert itinto 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 fornon-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-onitems 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.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 61

Radiator Fan Relay: Electrical Diagrams

Radiator Fan System With Heater

To view sheets referred to in these Diagrams, see NOTE: Diagram Information and Instructions/Complete Body and Chassis Diagrams

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation

Blower Motor Relay: Description and Operation

Chrysler does not use a Blower Motor Relay for these Year/Make/Model Vehicles.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

Compressor Clutch Relay: Locations

Power Distribution Center (Relay Locations)

Fuel Pump Relay Socket

Relay is located in LH side of engine compartment in the power distribution center.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 69

Compressor Clutch Relay: Description and Operation

A/C Fan And Clutch Relay Locations

PURPOSE

Supplies ground path for A/C compressor clutch.

OPERATION

Controlled by A/C or defrost switch (inside vehicle) and Powertrain Control Module (PCM). Relay receives battery voltage from radiator fan relay, (A/C relay will not energize unless the radiator fan relay is energized).

When A/C or defrost is selected, (turned ON), inside vehicle, and low and high pressure switches are closed, PCM receives an A/C ON signal.PCM then supplies relay ground.
If PCM senses Wide Open Throttle (WOT) or low idle speed condition, it removes relay ground, discontinueing A/C clutch engagement.
PCM delays activation of A/C relay for a specific period after engine start-up.

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations

Condenser Fan Motor Relay: Locations

Engine Compartment Components

RH Side Of Engine Compartment

> Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations

Relay Block

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T -

Harsh Shift At Low Speed/Speedo. Fluctuates

Speedometer Module: Customer InterestA/T - Harsh Shift At Low Speed/Speedo. Fluctuates

NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994

SUBJECT:Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVEDFROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THEREPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS:

1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)

NOTE:

THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILTPRIOR TO NOV. 1, 1994, MDH 11-11-XX.**

SYMPTOM/CONDITION:

**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomlyoccur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuateslightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plugwires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:

Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. IfDiagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If thefluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows:

If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drivegear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idleto 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does notremain at zero, perform the repair procedure.

If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With thetransmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary theengine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the outputRPM does not remain at zero, perform the repair procedure.
PARTS REQUIRED:

1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for

Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 85

Caravan V6-201 3.3L (1995)

AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:

This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing falsesignals into the output speed sensor wiring that connects to the Transmission Control Module (TCM).

1. Remove and discard the tie strap holding the wiring harness to the right engine mount.

2.
Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held tothe bracket with a tie strap. If so equipped, remove and discard the tie strap.

3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip.

4.
Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oildipstick clip to within 4 in. (100 mm) of the clip at the right engine mount.

**:NOTE

THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**

5.
Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/Ccompressor high pressure relief valve.**

6. Re-install the wiring harness and clip at the dip stick.

7.
Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal holein the engine mount bracket.

8.
Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicleoriginally had the wiring strapped to the spark plug separator bracket, replace the tie strap.

**9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.**

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for

Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 86

Caravan V6-201 3.3L (1995)

10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.

NOTE:

IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994COMPAK.**

POLICY:Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:Labor Operation No.

08-90-66-98 0.3 Hrs.

FAILURE CODE: XX - Service Adjustment

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec >

94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates

Speedometer Module: All Technical Service BulletinsA/T - Harsh Shift At Low Speed/Speedo. Fluctuates

NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994

SUBJECT:Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVEDFROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THEREPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS:

1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)

NOTE:

THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILTPRIOR TO NOV. 1, 1994, MDH 11-11-XX.**

SYMPTOM/CONDITION:

**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomlyoccur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuateslightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plugwires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:

Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. IfDiagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If thefluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows:

If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drivegear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idleto 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does notremain at zero, perform the repair procedure.

If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With thetransmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary theengine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the outputRPM does not remain at zero, perform the repair procedure.
PARTS REQUIRED:

1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service

Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 92

Caravan V6-201 3.3L (1995)

AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:

This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing falsesignals into the output speed sensor wiring that connects to the Transmission Control Module (TCM).

1. Remove and discard the tie strap holding the wiring harness to the right engine mount.

2.
Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held tothe bracket with a tie strap. If so equipped, remove and discard the tie strap.

3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip.

4.
Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oildipstick clip to within 4 in. (100 mm) of the clip at the right engine mount.

**:NOTE

THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**

5.
Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/Ccompressor high pressure relief valve.**

6. Re-install the wiring harness and clip at the dip stick.

7.
Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal holein the engine mount bracket.

8.
Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicleoriginally had the wiring strapped to the spark plug separator bracket, replace the tie strap.

**9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.**