Dodge Caravan 1997 User Manual

dodge :: Dodge Truck Caravan FWD V6-3.3L VIN
G Flex Fuel (1997)

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams

With A/C Part 7 Of 7

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 7

Radiator Cooling Fan Motor Relay: Testing and Inspection

(PCM)

Fan control is accomplished two ways. A pressure transducer on the compressor discharge line sends a signal to the Powertrain Control Module 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 coolanttemperature sensor which sends the message to the PCM. The fan will not run during cranking until the engine starts no matter what the coolanttemperature 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 todissipate 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 Trouble Code Tests and AssociatedProcedures/Manufacturer Code Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay

Power Distribution Center -- Under The Hood, Next To The Battery

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 13

Blower Motor Relay: LocationsRear Blower Relay

Rear Blower Motor Relay

This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams.

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

Blower Motor Relay: Description and OperationFront 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 thecontact 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 circuitF20. 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.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay > Page 16

Blower Motor Relay: Description and OperationRear 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. AtLOW and MEDIUM speeds, ground for the rear blower motor passes through the temperature sensor and one or more resistors, depending on speedselection.

Two switches operate the rear blower motor by supplying ground; the front control switch and the rear control switch. The front control switch mustbe in the ON position for the rear control switch to operate the rear blower motor.

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations

Relay Box: Locations

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 21

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection

Body Control Module: Testing and Inspection
SELF DIAGNOSTIC TEST

To activate self diagnostic program:1. With the ignition switch in the OFF position, depress the TRIP and RESET buttons.2. While holding the TRIP and RESET button turn the ignition switch to the ON position.3. Continue to hold the TRIP and RESET buttons until the word code appears in the odometer windows (about ) then release thefive seconds

buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists the code 999 (End Test) will momentarilyappear.

INSTRUMENT CLUSTER DTC CHART

DTC

Description

.........................................................................................................................................................................................................110 ......................................................................................................................................................................................... Memory Fault in cluster111 ...................................................................................................................................................................................... Calibration fault in cluster905 ......................................................................................................................................................................... No CCD bus messages from TCM921 ..................................................................................................................................................................................... Odometer fault from BCM940 ......................................................................................................................................................................... No CCD bus messages from PCM999 .......................................................................................................................................................................................................... End of Codes

For DTC testing see Condition Diagnostic Charts below.NOTE:

CONDITIONS

Refer to the following Diagnostic Charts:-

Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Instrument Cluster Diagnosis

- Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Speedometer Diagnosis

- Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Tachometer Diagnosis

- Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Fuel Gauge Diagnosis

- Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Temperature Diagnosis

- Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Odometer Diagnosis

­Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/DiagnosticCharts/Electronic Gear Indicator Display Diagnosis

­Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections See: Instrument Panel, Gauges and WarningIndicators/Testing and Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21)

CALIBRATION TEST

When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move sequentially through each calibration point. TheCalibration Table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If anygauge is out of calibration it will have to be calibrated using a scan tool (DRB III).

CLUSTER CALIBRATION TABLE

........................................................................................................................................................................................Speedometer Calibration Point

1 .......................................................................................................................................................................................................... 0 mph (0 Km/h)2 ...................................................................................................................................................................................................... 20 mph (40 Km/h)3 ...................................................................................................................................................................................................... 55 mph (80 Km/h)4 ..................................................................................................................................................................................................... 75 mph(120 Km/h)

.........................................................................................................................................................................................Tachometer Calibration Point

1 .......................................................................................................................................................................................................................... 0 rpm2 .................................................................................................................................................................................................................... 1000 rpm3 .................................................................................................................................................................................................................... 3000 rpm4 .................................................................................................................................................................................................................... 6000 rpm

..........................................................................................................................................................................................Fuel Gauge Calibration Point

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Testing and Inspection > Page 27

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

1 .................................................................................................................................................................................................................... Empty(E)2 .................................................................................................................................................................................................................... 1/8 Filled3 .................................................................................................................................................................................................................... 1/4 Filled4 ....................................................................................................................................................................................................................... Full (F)

...........................................................................................................................................................................Temperature Gauge Calibration Point

1 ..................................................................................................................................................................................................................... Cold (C)2 ............................................................................................................................................................................................................... Low Normal3 .............................................................................................................................................................................................................. High Normal4 ....................................................................................................................................................................................................................... Hot (H)

DIM TEST

When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays will dim down. If the VF display brightness does

no change, a problem exists in the cluster.

ODOMETER SEGMENT TEST

When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially If a segment in the odometer does notilluminate normally, a problem exists in the display.

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 thetransmission range indicator does not illuminate normally, a problem exists in the display board.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >

Technical Service Bulletins > Engine Controls - Service Manual Revisions

Powertrain Control Module: Technical Service BulletinsEngine Controls - Service Manual Revisions

NUMBER: 26-12-97E
GROUP: Miscellaneous
DATE: December, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN

Models:1997 2.4L, 3.0L, 3.3L, 3.8L Minivan Powertrain Diagnostic Manual - Publication Number - 81-699-96039
DESCRIPTION OF CHANGES
Revisions to the "No Cam Signal" at PCM test

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Service Manual Revisions > Page 32

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Service Manual Revisions > Page 33

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

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> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Service Manual Revisions > Page 34

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> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Service Manual Revisions > Page 35

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> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Service Manual Revisions > Page 36

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

49
Revision to the Idle "Air Control Circuit" procedure

147

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >

Diagrams > Connector Views

Powertrain Control Module: Connector Views

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Diagrams > Connector Views > Page 39

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

> 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

Automatic Shut Down (ASD) Relay: Diagrams

Refer to Diagrams/Electrical for wiring diagram information.

> 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

Automatic Shut Down (ASD) Relay: Diagrams

Refer to Diagrams/Electrical for wiring diagram information.

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 51

Air Bag Control Module: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module

Transmission Control Module

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 58

Power Control Module

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 59

Control Module: LocationsPower Distribution Center

Junction Block

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >

Transmission Control Module > Page 60

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

Power Distribution Center

Fuse Block

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 61

Power Control Module

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 62

Control Module: Description and Operation

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >

Page 63

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

The Transmission Control Module is the controlling unit for all electronic operations of the transaxle. The TCM receives information from(TCM)

several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other controlmodules on the CCD Bus.

Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desiredgear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation,and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:

- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle

- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles

(CVI)

The quick learn procedure is necessary to learn Clutch Volume Index . The TCM must learn the CVI of the transaxle if it is to be fully adaptive.The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear rangeduring the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis andperformed by the DRB Scan Tool.

The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan toolNOTE:

Emission regulations require the use of two labels after a flash update:

- Emission Modification Label

- Emission Part Number Modification Label

The following provides information on TCM identification and flash programming application:

1989 - 92

-

Original controllers were non-finned and are non-flashable

- Replacement controllers have fins with four heat sinks and are flashable

- Unique communications on CCD Data Bus for these year models

- Requires the use of Miller CH 5500 flash kit

1993 - 95

-

Original controllers were finned with four heat sinks and are flashable

- Replacement controllers have fins with four heat sinks and are flashable

- Unique communications on CCD Data Bus for these year models

- Requires the use of Miller CH 5500 flash kit

NOTE:

Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require awiring modification to pin 49.

1996

-

Original controllers were finned with seven heat sinks and are flashable

- Replacement controllers have fins with seven heat sinks and are flashable

- Unique communications on CCD Data Bus for these year models

- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information

Control Module: Service and RepairGeneral Information

Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a differentvehicle, 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.

If the Transmission Control Module has been replaced, the following procedures must be performed:NOTE:

- 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.

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 66

Control Module: Service and RepairReplacement

For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.NOTE:

REMOVAL

1. Disconnect the battery negative cable.

2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control
Module.

3. Remove Transmission Control Module mounting screws and lift module from vehicle.

INSTALLATION

To install, reverse removal procedures.

> 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 Relay

Transmission Control Relay

> 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 Relay > Page

71

Transmission Control System Relay: LocationsTransmission (Safety Shut-Down) Relay

Transmission Relay Location

> 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 Relay > Page 72

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

The Transmission Control Relay is located in LH side of engine compartment in the Power Distribution Center.

> 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 Relay > Page 73

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 74

Transmission Control Relay

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions

Wheel Speed Sensor: Technical Service BulletinsABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions

NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN

Models:1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 81

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 82

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> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 83

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> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 84

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> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 85

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> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 86

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51

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 87

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

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> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 88

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

57

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 89

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

59

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 90

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

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> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 91

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

67

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 92

Caravan FWD V6-3.3L VIN G Flex Fuel (1997)

69

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey

Hayes EBC-5H, EBC 310 Test Revisions > Page 93

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