Dodge Caravan 1997 FWD 2.4L Workshop Manual

dodge :: Dodge Truck Caravan FWD L4-2.4L VIN
X (1997)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Description and Operation

Audio Control Relay: Description and Operation
CIRCUIT OPERATION

This relay is located in the junction block and used along with the radio choke to control the switched battery feed to the amplifiers on thespeakers.

Power for the coil side of the relay is supplied on circuit X60. This circuit connects from the radio to the coil side of the relay and is HOT whenthe radio is ON only.
Ground for the coil side of the relay is supplied on circuit Z1 and terminates at the left side cowl.

10 Amp

Power for the contact side of the relay is supplied on circuit X12. This circuit is protected by a fuse located in cavity 8 of the junctionblock.
Battery voltage for the fuse is supplied on circuit A6. This circuit is HOT when the ignition switch is in the ACCESSORY and RUN position.

When the contacts in the relay CLOSE circuit X12 connects to circuit X1. Circuit X1 connects from the relay to the radio choke.

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

Remote Keyless Entry (RKE) Module

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 10

Remote Keyless Entry (RKE) Module

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module

Keyless Entry Module: Description and OperationRemote Keyless Entry Module
CIRCUIT OPERATION

(RKE)

Power for the Remote Keyless Entry module is supplied on circuit M1. This circuit is the Ignition Off Draw (IOD) circuit and is protectedby a fuse located in cavity 10 of the Power Distribution Center (PDC). This circuit is HOT at all times.10 Amp

Ground for the module is supplied on circuit Z2 and terminates at the instrument panel ground.

(BCM)

Circuit G96 is connected between the RKE module and the Body Control Module . This circuit supplies the BCM with information on theoperators request. The G96 circuit also supplied an input to the memory seat module.
Circuit D9 is connected from the RKE module to the BCM and is used for programming the RKE module.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module > Page 13

Keyless Entry Module: Description and OperationRemote Keyless Entry Module Input

The Remote Keyless Entry (RKE) module provides an input to the control module to indicate when the operator is unlocking the doors.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 14

Keyless Entry Module: Testing and Inspection

-

Check the circuit breaker located under the drivers seat30 Amp

-

Check the fuse located in cavity 2 of the PDC40 Amp

- Check the ground at the instrument panel left side cowl

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 15

Keyless Entry Module: Service and Repair
REMOVAL

1. Remove instrument panel top cover2. Remove screws holding RKE module to instrument panel.

RKE Module

3. Disconnect wire connector from RKE module.4. Remove the RKE module.

INSTALLATION

1. Install the RKE module.

RKE Module

2. Connect wire connector from RKE module.3. Install screws holding RKE module to instrument panel.4. Install instrument panel top cover

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

Remote Keyless Entry (RKE) Module

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 20

Remote Keyless Entry (RKE) Module

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module

Keyless Entry Module: Description and OperationRemote Keyless Entry Module
CIRCUIT OPERATION

(RKE)

Power for the Remote Keyless Entry module is supplied on circuit M1. This circuit is the Ignition Off Draw (IOD) circuit and is protectedby a fuse located in cavity 10 of the Power Distribution Center (PDC). This circuit is HOT at all times.10 Amp

Ground for the module is supplied on circuit Z2 and terminates at the instrument panel ground.

(BCM)

Circuit G96 is connected between the RKE module and the Body Control Module . This circuit supplies the BCM with information on theoperators request. The G96 circuit also supplied an input to the memory seat module.
Circuit D9 is connected from the RKE module to the BCM and is used for programming the RKE module.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module > Page 23

Keyless Entry Module: Description and OperationRemote Keyless Entry Module Input

The Remote Keyless Entry (RKE) module provides an input to the control module to indicate when the operator is unlocking the doors.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 24

Keyless Entry Module: Testing and Inspection

-

Check the circuit breaker located under the drivers seat30 Amp

-

Check the fuse located in cavity 2 of the PDC40 Amp

- Check the ground at the instrument panel left side cowl

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 25

Keyless Entry Module: Service and Repair
REMOVAL

1. Remove instrument panel top cover2. Remove screws holding RKE module to instrument panel.

RKE Module

3. Disconnect wire connector from RKE module.4. Remove the RKE module.

INSTALLATION

1. Install the RKE module.

RKE Module

2. Connect wire connector from RKE module.3. Install screws holding RKE module to instrument panel.4. Install instrument panel top cover

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

Junction Block

> 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 BulletinsMemory Power Seat - Travel Range

NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998

SUBJECT:Memory Power SeatTravel Range
MODELS:

1996-1999 (NS) Town & Country1996-1999 (GS) Chrysler Voyager1996-1998 (ZJ) Grand Cherokee1996-1998 (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 "softstop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motorend, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, nochange in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not runinto 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 causesthe 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, positionsthat 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 lastparagraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seatoperation.

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 tobe 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 pathor 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 P34connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locksout" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34connector 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 thesecond 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 THECUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED INTHE SERVICE MANUAL).

POLICY: Information Only

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation

ABS Main Relay: Description and Operation

Fuse Locations In Power Distribution Center

FUSES

(PDC)

The ABS pump motor and the entire system have their own fuses. These are located in the Power Distribution Center . The PDC is locatedon the drivers side of the engine compartment forward of the strut tower.

RELAYS

On the Teves Mark 20 Antilock Brake System, both the pump motor relay and the system relay are located in the Controller Antilock Brake . If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. (CAB)

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

CAB 25 Way Connector

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

Electronic Brake Control Module: 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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and Instructions > Page 42

Caravan FWD L4-2.4L VIN X (1997)

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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Caravan FWD L4-2.4L VIN X (1997)

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.

Electrostatic Discharge (ESD) Sensitive Devices

Electrostatic Discharge Symbol

(ESD)

All Electrostatic Discharge sensitive components are solid state and a symbol is used to indicate this. When handling any component with thissymbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into thecomponent. 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

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.

Notes, Cautions and Warnings

Additional important information is presented in three ways: Notes, Cautions, and Warnings.

NOTES

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Caravan FWD L4-2.4L VIN X (1997)

are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate differentconditions that may appear on the vehicle. For example, an up-to and after condition.

are used to indicate information that could prevent making an error that may damage the vehicle.CAUTIONS

WARNINGS

provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time avehicle 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. AMANUAL 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), TAILPIPE, 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 thejunction 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.

Symbols

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

and Instructions > Page 45

Caravan FWD L4-2.4L VIN X (1997)

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

and Instructions > Page 46

Caravan FWD L4-2.4L VIN X (1997)

Symbol Identification

Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart.

Take-Outs

The abbreviation is used in the component location section to indicate a point at which the wiring harness branches out to a component.T/O

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

Connector and Splice Identification

The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letterdesignations follows:

- B - Body or EDW harness

- C - Dome harness

- D - Door harness

- E - Engine harness

- F - Fuel rail harness

- J - Jumper harness

- L - Liftgate harness

- P - Instrument panel harness

- S - Seat harness

- T - Trailer tow harness

When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally thesplice number. An example of this would be ESO2.

- E - Indicates splice is in the engine harness

- S - Indicates a splice

- 02 - Indicates what splice it is in harness

Wire Color Codes

Wire Color Code Identification

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

and Instructions > Page 47

Caravan FWD L4-2.4L VIN X (1997)

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. The color is shownas a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk willfollow the main wire color. If the tracer is non-standard, the main wire color will have a slash after it, followed by the tracer color.(/)

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

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.

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

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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. 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.

ends of the tubing.

14. Repeat steps 8 through 13 for each wire.15. Re-tape the wire harness starting behind the connector and past the repair.1-1/2 inches 2 inches

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.

Connector Locking Wedge

3. Remove the connector locking wedge, if required.

Terminal Removal

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Caravan FWD L4-2.4L VIN X (1997)

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

Diode Identification

Do not use acid core solder.

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. 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.

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

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Caravan FWD L4-2.4L VIN X (1997)

Connnector Locking Wedge Tab (Typical)

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.

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.

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

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Caravan FWD L4-2.4L VIN X (1997)

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.

Molex Connector Repair

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

Using Special Tool 6742

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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.

Terminal/Connector Repair-Thomas and Betts Connectors

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

Thomas And Betts Connector Lock Release Tabs

3. Push in the two lock tabs on the side of the connector.

Removing Wire Terminal

6934
6934

4. Insert the probe end of Special Tool into the back of the connector cavity.5. Grasp the wire and Special Tool and slowly remove the wire and terminal from the connector.6. Repair or replace the terminal.7. Install the wire and terminal in the connector. Fully seat the terminal in the connector.

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Caravan FWD L4-2.4L VIN X (1997)

Single Lock Tab

8. Push in the single lock tab on the side of the connector.

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

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

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Caravan FWD L4-2.4L VIN X (1997)

Probing Tool Package 6807

Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

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Electronic Brake 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 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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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.

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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

- 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 - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 58

Controller Antilock Brake

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 59

CAB Power Feed Circuit Schematic

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 60

Electronic Brake Control Module: Service Precautions

(CAB) (HCU)

The Controller Anti-Lock Brake is mounted to the bottom of the Hydraulic Control Unit . Therefore, it is important to observe thefollowing HCU precautions and service notes.

CAUTION:

- Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected.

­Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling intothe ports of HCU or entering the brake tubes.

-

The HCU 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 HCU bracket to the front suspensioncrossmember.

-

Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, thebrake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle componentswhen installed.

Brake Tube Connections To HCU

­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 above 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 HCU mounting bracket.

- Before installing the 25 way connector in the CAB, be sure the seal is properly installed in the connector.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 61

Electronic Brake Control Module: Description and Operation

(CAB)

The Controller Antilock Brake is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CABcontains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared tomake sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock Brake System amber warning lamp.(ABS)

The primary functions of the CAB are to:

- detect wheel locking tendencies

- control fluid pressure modulation to the brakes during antilock stop

- monitor the system for proper operation

- provide communication to the DRB while in diagnostic mode

- store diagnostic information in non-volatile memory

The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve tomodulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system with the use of 2accumulators. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turnson the pump motor during an antilock stop.

The antilock brake system is constantly monitored by the CAB for proper operation If the CAB detects a system malfunction, it can disable the antilocksystem and turn on the ABS warning lamp. If the antilock function is disabled, the system will revert to standard base brake system operation.

CAB Inputs Include The Following:

- ABS Warning Lamp

- Diagnostic Communication

- Four Wheel Speed Sensors

- Ignition Switch

- Fused B+

- Stop Lamp Switch

- Traction Control Switch

CAB Outputs Include The Following:

- ABS Warning Light Actuation

- Voltage

- Eight Valves

- Ten Valves With Traction Control

- Diagnostic Communication

- Body Controller Communication

- Traction Control Lamp Illumination

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal

Electronic Brake Control Module: Service and RepairRemoval
PROCEDURE

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 Hydraulic Control Unit .(HCU)

3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist.

Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected.CAUTION:

CAB 25 Way Connector

Unlocking CAB 25 Way Connector

4. Remove the 25 way connector from the Controller Antilock Brake located on the bottom of the HCU. The 25 way connector is removed(CAB)

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 unlock and raisethe 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 particlesfrom falling into the ports of HCU or entering the brake tubes.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal >

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Caravan FWD L4-2.4L VIN X (1997)

5. 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.

Brake Tube Connections To HCU

6. Remove the brake tubes 6.from the inlet and outlet ports on the HCU.

HCU To Suspension Cradle Mounting Bolts

7. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember.8. Remove HCU and the mounting bracket as a unit from the vehicle.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal >

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Caravan FWD L4-2.4L VIN X (1997)

HCU Mounting Bolts

9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the mounting bracket.

Pump Motor To CAB Wiring Harness

10. Unplug the pump motor wiring harness from the CAB.

CAB Attaching Bolts

11. Remove the 4 bolts attaching the CAB to the valve block of the HCU.

Remove/Install CAB

12. Remove the CAB from the valve block of the HCU.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 66

Electronic Brake Control Module: Service and RepairInstallation
PROCEDURE

Remove/Install CAB

1. Install the Controller Antilock Brake on the valve block of the Hydraulic Control Unit .(CAB) (HCU)

CAB Attaching Bolts

2. Install the 4 bolts mounting the CAB to the valve block of the HCU. Tighten the CAB mounting bolts to a torque of .2 Nm (17 inch lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal >

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Pump Motor To CAB Wiring Harness

3. Plug the pump/motor wiring harness into the CAB.

HCU Mounting Bolts

4. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting bracket. Tighten the 3 mounting bolts to a torque

of .11 Nm (97 inch lbs.)

CAUTION:

The HCU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a specialaluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the HCU bracket to thefront suspension crossmember.

HCU To Suspension Cradle Mounting Bolts

5. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the HCU bracket to the

crossmember. Tighten the 3 mounting bolts to a torque of .28 Nm (250 inch lbs.)

CAUTION:

Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and theproportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other orother vehicle components when installed.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal >

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Brake Tube Connections To HCU

CAUTION:

When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure properABS operation. Refer to above image for the correct chassis brake tube locations.

The chassis brake tube attachment locations to the HCU, are marked on the bottom of the HCU mounting bracket.NOTE:

6. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown above. Tighten the tube nuts to a torque of 17
.Nm (146 inch lbs.)

Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector.NOTE:

Unlocking CAB 25 Way Connector

7. 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 theconnector into the socket of the CAB and lock it in the installed position.

Brake Tube Routing Clips

8. Install the routing clips on the brake tubes.9. Lower vehicle.

10. Connect negative cable back on negative post of the battery.11. Bleed the base brakes and the ABS brake hydraulic system.

See: Brakes and Traction Control/Brake Bleeding

12. Road test vehicle to ensure proper operation of the base and ABS brake systems.

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

Radiator Cooling Fan Motor Relay: Locations

Cooling Fan Relay Location

Radiator Fan Relay Mounted On Left Front Frame Rail

> 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

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

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

Instructions > Page 75

Caravan FWD L4-2.4L VIN X (1997)

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.

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

Instructions > Page 76

Caravan FWD L4-2.4L VIN X (1997)

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.

Electrostatic Discharge (ESD) Sensitive Devices

Electrostatic Discharge Symbol

(ESD)

All Electrostatic Discharge sensitive components are solid state and a symbol is used to indicate this. When handling any component with thissymbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into thecomponent. 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

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.

Notes, Cautions and Warnings

Additional important information is presented in three ways: Notes, Cautions, and Warnings.

NOTES

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

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Caravan FWD L4-2.4L VIN X (1997)

are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate differentconditions that may appear on the vehicle. For example, an up-to and after condition.

are used to indicate information that could prevent making an error that may damage the vehicle.CAUTIONS

WARNINGS

provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time avehicle 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. AMANUAL 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), TAILPIPE, 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 thejunction 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.

Symbols

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Instructions > Page 78

Caravan FWD L4-2.4L VIN X (1997)