Dodge Grand Caravan 1996 2.4L DOHC Workshop Manual

dodge :: Dodge Truck Grand Caravan L4-2.4L
DOHC (1996)

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

Audio Control Relay: Locations

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 7

Grand Caravan L4-2.4L DOHC (1996)

Junction Block (Part 1 Of 5)

Junction Block (Part 5 Of 5)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 8

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.

20 Amp

Power for the contact side of the relay is supplied on circuit F62. This circuit is protected by a fuse located in cavity 7 of the junctionblock.

40 Amp

Battery voltage for the fuse is supplied on circuit A6. This circuit is HOT at all times and protected by a fuse located in cavity 6 of thePower Distribution Center (PDC).
When the contacts in the relay CLOSE circuit F62 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 12

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 15

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

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 16

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 > 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 - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 19

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 > 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 24

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 27

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

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 28

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 > 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 31

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 > Power Door Lock Relay > Component Information > Locations

Relay Locations

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 35

Power Door Lock Relay: Diagrams

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 36

Grand Caravan L4-2.4L DOHC (1996)

Junction Block (Part 1 Of 5)

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 37

Grand Caravan L4-2.4L DOHC (1996)

Junction Block (Part 3 Of 5)

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 38

Grand Caravan L4-2.4L DOHC (1996)

Junction Block (Part 4 Of 5)

Junction Block (Part 5 Of 5)

> 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 > Locations

ABS Main Relay: Locations

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 47

Grand Caravan L4-2.4L DOHC (1996)

Junction Block (Part 1 Of 5)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 48

Grand Caravan L4-2.4L DOHC (1996)

Junction Block (Part 4 Of 5)

Instrument Panel Connections

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 49

ABS Main Relay: Description and Operation
CIRCUIT OPERATION

10 Amp

The ABS main relay is used for the operation of the ABS system. Power for the coil side of the relay is supplied on circuit A22. This circuit (A22)is powered by circuit A2 when the ignition switch is in the RUN position. Circuit A2 is protected by a fuse located in cavity 10 of thejunction block. Power for the fuse is supplied by circuit A6 from the Power Distribution Center .(PDC)

The ground side of the coil is controlled by the ABS control module on circuit B58. This circuit connects to cavity 32 of the control module.

Power for the contact side of the relay is supplied by circuit A20. This circuit is protected by a fuse located in cavity 17 of the PDC.25 Amp

When the relay is energized, the relay moves from its normally grounded position to connect circuits A20 and B47. Circuit B47 supplies aswitched battery voltage to the ABS control module, and to the ABS hydraulic valves.

The relay is located on the PDC and is normally grounded in the OFF position. The ground is provided on circuit Z1 and terminates at the leftcowl panel.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 50

ABS Main Relay: Service and Repair

1. Disconnect battery ground cable, then remove lower lefthand kick panel.

ABS Relay.

2. Pull relay straight out of junction block, without twisting.3. Reverse procedure to install.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations

Power Distribution (Part 1 Of 5)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations > Page 54

Brake Fluid Pump Relay: Description and Operation
CIRCUIT OPERATION

(PDC)

The ABS pump motor relay. located in the Power Distribution Center , is used to control the operation of the pump motor Power for thecoil side of the relay is supplied by circuit B47. This circuit is HOT when the ABS main relay is energized.
Ground for the coil side of the relay is controlled by the ABS control module on circuit B116.

Power for the contact side of the relay is supplied by circuit A10. This circuit is protected by a fuse located in cavity 7 of the PDC.40 Amp

When the control module grounds circuit B116 the contacts in the relay CLOSE connecting circuits A10and B120. Circuit B120 connects from therelay to the pump motor.
The B120 circuit is spliced and provides an input to the ABS control module for pump motor sense.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations > Page 55

Brake Fluid Pump Relay: Service and Repair

1. Disconnect and isolate battery ground cable, then remove power distribution center cover to access relay.

Pump/Motor Relay Location.

2. Remove relay from power distribution center, by pulling straight upward without twisting.3. Reverse procedure to install.

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

Electronic Brake Control Module: Description and Operation

(HCU)

(CAB)

This microprocessing device, located below the instrument panel near the brake pedal bracket, monitors wheel speeds in order to detect wheel lock-upand modulates fluid pressure accordingly via the Hydraulic Control Unit . The device also monitors the system for proper operation, storesdiagnostic information and communicates with diagnostic scan tools when necessary. The Controller Anti-lock Brake is responsible for theillumination of the amber ABS warning lamp in the event of a malfunction.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Page 59

Electronic Brake Control Module: Service and Repair

1. With ignition switch in Off position, remove -way Controller Anti-lock Brake connector retaining bolt, then disconnect connector from60 (CAB)

unit.

2. Remove two nuts securing CAB bracket to brake pedal bracket, then remove CAB from vehicle.3. Reverse procedure to install, noting the following:

a. When installing CAB connector, seat connector into CAB as much as possible by hand, then seat fully with retaining bolt.b. CAB bracket nuts to ft. lbs. and connector retaining bolt to inch lbs.Torque 21 35

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 8251 > Oct > 99 > Recall - Radiator fan Relay

Technical Service Bulletin # 8251

Recall - Radiator fan Relay

No8251
October 1999
Models
1996 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country

Emissions Recall No. 8251 (Vehicles Located Out of California)Emissions Recall No. 8252 (Vehicles Located in California)Radiator Fan Relay
Subject

The radiator fan relay on about 635,000 of the above vehicles may not turn on the radiator fans. This may cause the engine to overheat. In addition,radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S.Environmental Protection Agency (EPA) and California Air Resources Board (CARB) emission regulations.
Repair

The radiator fan relay must be replaced.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full servicefacility special equipment and is a DaimlerChrysler Mobile Service approved repair.
Parts Information

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough radiator fan relaypackages to service 25% of those vehicles.
Part Number Description
CLX38250 Radiator Fan Relay Package
Each repair package contains one radiator fan relay and two relay mounting screws.

Dealers servicing vehicles registered in the state of California (Recall No.8252) must also order the required Authorized Modifications Label, PN94275086, as necessary to support scheduled repairs.
Service Procedure
A. Replace Radiator Fan Relay

1. With the ignition key in the OFF position, disconnect the negative battery cable.

NOTE:

To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8251 > Oct > 99 > Recall - Radiator fan Relay > Page 69

Grand Caravan L4-2.4L DOHC (1996)

2. On 3.OL, 3.3L and 3.8L engines, remove the two (2) screws that attach the air inlet resonator to the upper radiator support.

3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.

4. Remove the air cleaner housing.

FIGURE 1

5. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 1).

6. Disconnect the radiator fan relay wiring connector.

7. Remove the radiator fan relay. Discard the relay and the attaching screws.

8. Clean the left frame rail where the old relay was mounted with a clean cloth.

9. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m).

CAUTION:

Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the providedscrews.

10. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.

11. Install the air cleaner housing.

12. Install the resonator assembly and connect the upper and lower air inlet hoses.

13. Install the resonator to upper radiator support screws. Tighten the screws securely.

14. Connect the negative battery cable.

B. Install the Authorized Modifications Label:

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8251 > Oct > 99 > Recall - Radiator fan Relay > Page 70

Grand Caravan L4-2.4L DOHC (1996)

FIGURE 2

Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the labelnear the VECI label.

C. Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission RecallProof of Correction Form (Form No.81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall hasbeen performed when they renew the vehicle registration.

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recallservice completions and provide dealer payments.
Use the following labor operation number and time allowance:

Labor Operation Time
Number Allowance

Replace radiator fan relay 08825182 0.4 hours
Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE:

See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and theMDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the samestreet address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners knownto DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP

All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to scheduleappointments for this service with their dealers. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealerreference as needed.
Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reasonon a postcard and mail to:

DaimlerChrysler CorporationCIMS 482-00-85800 Chrysler Drive EastAuburn Hills, Michigan 48326-2757

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8251 > Oct > 99 > Recall - Radiator fan Relay > Page 71

Grand Caravan L4-2.4L DOHC (1996)

Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed ifknown. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTERFUNCTION" prompt, then type "0RD8251" (vehicles located out of California) or "0RD8252" (vehicles located in California).

Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.

Owner Letter (Federal Vehicles)

DAIMLERCHRYSLER
EMISSIONS RECALL TO REPLACE YOUR MINI VAN'S RADIATOR FAN RELAY
Dear DaimlerChrysler Minivan Owner:

DaimlerChrysler has determined that some 1996 Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Countryminivans may be in violation of Federal emissions regulations.
The problem is...

The radiator fan relay on your minivan (identified on the enclosed form) may not turn on the radiator cooling fans. This may cause your engine tooverheat. In addition, radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitoredcomponent violates U.S. Environmental Protection Agency (EPA) emission regulations.
What DaimlerChrysler and your Dealer will do...

DaimlerChrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay. The work will takeabout 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
What you must do...
Simply contact your dealer right away to schedule a service appointment.
Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer.
If you need help...

If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. Arepresentative will assist you in getting your vehicle repaired.

In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law and your right to participate infuture recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack ofproper maintenance of your vehicle. Further, without this repair, your vehicle may fail a state or local emission inspection test.

We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you foryour attention to this important matter.

Owner Letter (California Vehicles)

DAIMLERCHRYSLER
EMISSIONS RECALL TO REPLACE YOUR MINIVAN'S RADIATOR FAN RELAY
Dear DaimlerChrysler Minivan Owner:

DaimlerChrysler has determined that some 1996 Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Countryminivans may be in violation of California emissions regulations.
The problem is...

The radiator fan relay on your minivan (identified on the enclosed form) may not turn on the radiator cooling fans. This may cause your engine tooverheat. In addition, radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitoredcomponent violates California Air Resources Board (CARB) emission regulations.
What DaimlerChrysler and your dealer will do...

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8251 > Oct > 99 > Recall - Radiator fan Relay > Page 72

Grand Caravan L4-2.4L DOHC (1996)

DaimlerChrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay. The work will takeabout 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
What you must do...

Simply contact your dealer right away to schedule a service appointment.
Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer.
If you live in California and don't get this done...

The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that everyvehicle must pass an emission test (SMOG Check) every two yearsand before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs.

How the state knows that the recall has been performed...

State of California regulations require DaimlerChrysler to provide theDepartment of Motor Vehicles with a record of all vehicles that have nothad the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recallhas been completed.

Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this formsince the California Department of Motor Vehicles may require that you supply it as proof of recall completion.

If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at1-800-992-1997. A representative will assist you in getting your vehiclerepaired.

In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon aspossible. Failure to do so could be determined as lack of proper maintenance of your vehicle.

We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you foryour attention to this important matter.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 8252 > Oct > 99 > Recall - Radiator Fan relay

Technical Service Bulletin # 8252

Recall - Radiator Fan relay

No8252
October 1999
Models
1996 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country

Emissions Recall No. 8251 (Vehicles Located Out of California)Emissions Recall No. 8252 (Vehicles Located in California)Radiator Fan Relay
Subject

The radiator fan relay on about 635,000 of the above vehicles may not turn on the radiator fans. This may cause the engine to overheat. In addition,radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S.Environmental Protection Agency (EPA) and California Air Resources Board (CARB) emission regulations.
Repair

The radiator fan relay must be replaced.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full servicefacility special equipment and is a DaimlerChrysler Mobile Service approved repair.
Parts Information

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough radiator fan relaypackages to service 25% of those vehicles.
Part Number Description
CLX38250 Radiator Fan Relay Package
Each repair package contains one radiator fan relay and two relay mounting screws.

Dealers servicing vehicles registered in the state of California (Recall No.8252) must also order the required Authorized Modifications Label, PN94275086, as necessary to support scheduled repairs.
Service Procedure
A. Replace Radiator Fan Relay

1. With the ignition key in the OFF position, disconnect the negative battery cable.

NOTE:

To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8252 > Oct > 99 > Recall - Radiator Fan relay > Page 77

Grand Caravan L4-2.4L DOHC (1996)

2. On 3.OL, 3.3L and 3.8L engines, remove the two (2) screws that attach the air inlet resonator to the upper radiator support.

3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.

4. Remove the air cleaner housing.

FIGURE 1

5. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 1).

6. Disconnect the radiator fan relay wiring connector.

7. Remove the radiator fan relay. Discard the relay and the attaching screws.

8. Clean the left frame rail where the old relay was mounted with a clean cloth.

9. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m).

CAUTION:

Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the providedscrews.

10. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.

11. Install the air cleaner housing.

12. Install the resonator assembly and connect the upper and lower air inlet hoses.

13. Install the resonator to upper radiator support screws. Tighten the screws securely.

14. Connect the negative battery cable.

B. Install the Authorized Modifications Label:

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8252 > Oct > 99 > Recall - Radiator Fan relay > Page 78

Grand Caravan L4-2.4L DOHC (1996)

FIGURE 2

Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the labelnear the VECI label.

C. Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission RecallProof of Correction Form (Form No.81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall hasbeen performed when they renew the vehicle registration.

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recallservice completions and provide dealer payments.
Use the following labor operation number and time allowance:

Labor Operation Time
Number Allowance

Replace radiator fan relay 08825182 0.4 hours
Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE:

See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and theMDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the samestreet address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners knownto DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP

All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to scheduleappointments for this service with their dealers. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealerreference as needed.
Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reasonon a postcard and mail to:

DaimlerChrysler CorporationCIMS 482-00-85800 Chrysler Drive EastAuburn Hills, Michigan 48326-2757

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8252 > Oct > 99 > Recall - Radiator Fan relay > Page 79

Grand Caravan L4-2.4L DOHC (1996)

Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed ifknown. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTERFUNCTION" prompt, then type "0RD8251" (vehicles located out of California) or "0RD8252" (vehicles located in California).

Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.

Owner Letter (Federal Vehicles)

DAIMLERCHRYSLER
EMISSIONS RECALL TO REPLACE YOUR MINI VAN'S RADIATOR FAN RELAY
Dear DaimlerChrysler Minivan Owner:

DaimlerChrysler has determined that some 1996 Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Countryminivans may be in violation of Federal emissions regulations.
The problem is...

The radiator fan relay on your minivan (identified on the enclosed form) may not turn on the radiator cooling fans. This may cause your engine tooverheat. In addition, radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitoredcomponent violates U.S. Environmental Protection Agency (EPA) emission regulations.
What DaimlerChrysler and your Dealer will do...

DaimlerChrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay. The work will takeabout 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
What you must do...
Simply contact your dealer right away to schedule a service appointment.
Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer.
If you need help...

If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. Arepresentative will assist you in getting your vehicle repaired.

In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law and your right to participate infuture recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack ofproper maintenance of your vehicle. Further, without this repair, your vehicle may fail a state or local emission inspection test.

We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you foryour attention to this important matter.

Owner Letter (California Vehicles)

DAIMLERCHRYSLER
EMISSIONS RECALL TO REPLACE YOUR MINIVAN'S RADIATOR FAN RELAY
Dear DaimlerChrysler Minivan Owner:

DaimlerChrysler has determined that some 1996 Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Countryminivans may be in violation of California emissions regulations.
The problem is...

The radiator fan relay on your minivan (identified on the enclosed form) may not turn on the radiator cooling fans. This may cause your engine tooverheat. In addition, radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitoredcomponent violates California Air Resources Board (CARB) emission regulations.
What DaimlerChrysler and your dealer will do...

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: >

8252 > Oct > 99 > Recall - Radiator Fan relay > Page 80

Grand Caravan L4-2.4L DOHC (1996)

DaimlerChrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay. The work will takeabout 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
What you must do...

Simply contact your dealer right away to schedule a service appointment.
Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer.
If you live in California and don't get this done...

The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that everyvehicle must pass an emission test (SMOG Check) every two yearsand before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs.

How the state knows that the recall has been performed...

State of California regulations require DaimlerChrysler to provide theDepartment of Motor Vehicles with a record of all vehicles that have nothad the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recallhas been completed.

Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this formsince the California Department of Motor Vehicles may require that you supply it as proof of recall completion.

If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at1-800-992-1997. A representative will assist you in getting your vehiclerepaired.

In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon aspossible. Failure to do so could be determined as lack of proper maintenance of your vehicle.

We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you foryour attention to this important matter.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor

Relay: > 8251 > Oct > 99 > Recall - Radiator fan Relay

Technical Service Bulletin # 8251

Recall - Radiator fan Relay

No8251
October 1999
Models
1996 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country

Emissions Recall No. 8251 (Vehicles Located Out of California)Emissions Recall No. 8252 (Vehicles Located in California)Radiator Fan Relay
Subject

The radiator fan relay on about 635,000 of the above vehicles may not turn on the radiator fans. This may cause the engine to overheat. In addition,radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S.Environmental Protection Agency (EPA) and California Air Resources Board (CARB) emission regulations.
Repair

The radiator fan relay must be replaced.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full servicefacility special equipment and is a DaimlerChrysler Mobile Service approved repair.
Parts Information

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough radiator fan relaypackages to service 25% of those vehicles.
Part Number Description
CLX38250 Radiator Fan Relay Package
Each repair package contains one radiator fan relay and two relay mounting screws.

Dealers servicing vehicles registered in the state of California (Recall No.8252) must also order the required Authorized Modifications Label, PN94275086, as necessary to support scheduled repairs.
Service Procedure
A. Replace Radiator Fan Relay

1. With the ignition key in the OFF position, disconnect the negative battery cable.

NOTE:

To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Radiator Cooling Fan Motor Relay: > 8251 > Oct > 99 > Recall - Radiator fan Relay > Page 86

Grand Caravan L4-2.4L DOHC (1996)

2. On 3.OL, 3.3L and 3.8L engines, remove the two (2) screws that attach the air inlet resonator to the upper radiator support.

3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.

4. Remove the air cleaner housing.

FIGURE 1

5. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 1).

6. Disconnect the radiator fan relay wiring connector.

7. Remove the radiator fan relay. Discard the relay and the attaching screws.

8. Clean the left frame rail where the old relay was mounted with a clean cloth.

9. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m).

CAUTION:

Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the providedscrews.

10. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.

11. Install the air cleaner housing.

12. Install the resonator assembly and connect the upper and lower air inlet hoses.

13. Install the resonator to upper radiator support screws. Tighten the screws securely.

14. Connect the negative battery cable.

B. Install the Authorized Modifications Label:

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Radiator Cooling Fan Motor Relay: > 8251 > Oct > 99 > Recall - Radiator fan Relay > Page 87

Grand Caravan L4-2.4L DOHC (1996)

FIGURE 2

Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the Authorized Modifications Label. Then attach the labelnear the VECI label.

C. Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission RecallProof of Correction Form (Form No.81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall hasbeen performed when they renew the vehicle registration.

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recallservice completions and provide dealer payments.
Use the following labor operation number and time allowance:

Labor Operation Time
Number Allowance

Replace radiator fan relay 08825182 0.4 hours
Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE:

See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and theMDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the samestreet address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners knownto DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP

All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to scheduleappointments for this service with their dealers. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealerreference as needed.
Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reasonon a postcard and mail to:

DaimlerChrysler CorporationCIMS 482-00-85800 Chrysler Drive EastAuburn Hills, Michigan 48326-2757

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Radiator Cooling Fan Motor Relay: > 8251 > Oct > 99 > Recall - Radiator fan Relay > Page 88

Grand Caravan L4-2.4L DOHC (1996)

Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed ifknown. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTERFUNCTION" prompt, then type "0RD8251" (vehicles located out of California) or "0RD8252" (vehicles located in California).

Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.

Owner Letter (Federal Vehicles)

DAIMLERCHRYSLER
EMISSIONS RECALL TO REPLACE YOUR MINI VAN'S RADIATOR FAN RELAY
Dear DaimlerChrysler Minivan Owner:

DaimlerChrysler has determined that some 1996 Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Countryminivans may be in violation of Federal emissions regulations.
The problem is...

The radiator fan relay on your minivan (identified on the enclosed form) may not turn on the radiator cooling fans. This may cause your engine tooverheat. In addition, radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitoredcomponent violates U.S. Environmental Protection Agency (EPA) emission regulations.
What DaimlerChrysler and your Dealer will do...

DaimlerChrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay. The work will takeabout 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
What you must do...
Simply contact your dealer right away to schedule a service appointment.
Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer.
If you need help...

If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. Arepresentative will assist you in getting your vehicle repaired.

In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law and your right to participate infuture recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack ofproper maintenance of your vehicle. Further, without this repair, your vehicle may fail a state or local emission inspection test.

We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you foryour attention to this important matter.

Owner Letter (California Vehicles)

DAIMLERCHRYSLER
EMISSIONS RECALL TO REPLACE YOUR MINIVAN'S RADIATOR FAN RELAY
Dear DaimlerChrysler Minivan Owner:

DaimlerChrysler has determined that some 1996 Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Countryminivans may be in violation of California emissions regulations.
The problem is...

The radiator fan relay on your minivan (identified on the enclosed form) may not turn on the radiator cooling fans. This may cause your engine tooverheat. In addition, radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitoredcomponent violates California Air Resources Board (CARB) emission regulations.
What DaimlerChrysler and your dealer will do...

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Radiator Cooling Fan Motor Relay: > 8251 > Oct > 99 > Recall - Radiator fan Relay > Page 89

Grand Caravan L4-2.4L DOHC (1996)

DaimlerChrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay. The work will takeabout 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
What you must do...

Simply contact your dealer right away to schedule a service appointment.
Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer.
If you live in California and don't get this done...

The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that everyvehicle must pass an emission test (SMOG Check) every two yearsand before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs.

How the state knows that the recall has been performed...

State of California regulations require DaimlerChrysler to provide theDepartment of Motor Vehicles with a record of all vehicles that have nothad the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recallhas been completed.

Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this formsince the California Department of Motor Vehicles may require that you supply it as proof of recall completion.

If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at1-800-992-1997. A representative will assist you in getting your vehiclerepaired.

In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon aspossible. Failure to do so could be determined as lack of proper maintenance of your vehicle.

We are sorry for any inconvenience but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you foryour attention to this important matter.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor

Relay: > 8252 > Oct > 99 > Recall - Radiator Fan relay

Technical Service Bulletin # 8252

Recall - Radiator Fan relay

No8252
October 1999
Models
1996 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country

Emissions Recall No. 8251 (Vehicles Located Out of California)Emissions Recall No. 8252 (Vehicles Located in California)Radiator Fan Relay
Subject

The radiator fan relay on about 635,000 of the above vehicles may not turn on the radiator fans. This may cause the engine to overheat. In addition,radiator fan relay operation is monitored by the vehicle's On-Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S.Environmental Protection Agency (EPA) and California Air Resources Board (CARB) emission regulations.
Repair

The radiator fan relay must be replaced.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full servicefacility special equipment and is a DaimlerChrysler Mobile Service approved repair.
Parts Information

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough radiator fan relaypackages to service 25% of those vehicles.
Part Number Description
CLX38250 Radiator Fan Relay Package
Each repair package contains one radiator fan relay and two relay mounting screws.

Dealers servicing vehicles registered in the state of California (Recall No.8252) must also order the required Authorized Modifications Label, PN94275086, as necessary to support scheduled repairs.
Service Procedure
A. Replace Radiator Fan Relay

1. With the ignition key in the OFF position, disconnect the negative battery cable.

NOTE:

To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Radiator Cooling Fan Motor Relay: > 8252 > Oct > 99 > Recall - Radiator Fan relay > Page 94

Grand Caravan L4-2.4L DOHC (1996)

2. On 3.OL, 3.3L and 3.8L engines, remove the two (2) screws that attach the air inlet resonator to the upper radiator support.

3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.

4. Remove the air cleaner housing.

FIGURE 1

5. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 1).

6. Disconnect the radiator fan relay wiring connector.

7. Remove the radiator fan relay. Discard the relay and the attaching screws.

8. Clean the left frame rail where the old relay was mounted with a clean cloth.

9. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m).

CAUTION:

Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the providedscrews.

10. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.

11. Install the air cleaner housing.

12. Install the resonator assembly and connect the upper and lower air inlet hoses.

13. Install the resonator to upper radiator support screws. Tighten the screws securely.

14. Connect the negative battery cable.

B. Install the Authorized Modifications Label: