Engine Controls - Remove/install/overhaul - 3.0L: Removal & Installation Dodge Caravan III

Removal & Installation

1. The PCM is located between driver's side front fender and power distribution center, near battery. (Scheme 29) Disconnect negative battery cable and then positive battery cable from battery.
2. Remove bolts on side of power distribution center that secure power distribution center to mounting bracket. Remove heat shield from outside of battery. Remove battery.
3. Rotate power distribution center toward the engine to disengage power distribution center from rear mounting bracket. Pull power distribution center toward rear of vehicle to disengage power distribution center from front mounting bracket.
4. Allow power distribution center to lay aside for access to PCM. Remove electrical connectors from PCM. Electrical connectors may be removed by squeezing tabs on electrical connector together and pulling electrical connector from PCM. Remove bolts and PCM. To install, reverse removal procedure.

Scheme 29

1. The TCM is located on passenger's side front corner of engine compartment, on inner fender, near windshield washer reservoir. (Scheme 30)
2. Disconnect negative battery cable. Loosen retaining bolt at center of 60-pin electrical connector on TCM. Disconnect electrical connector from TCM. Remove screws and TCM. To install, reverse removal procedure.

Scheme 30

1. The A/C pressure sensor is located on A/C refrigerant line on firewall, near front of generator and contains a Gray 4-pin electrical connector. Disconnect electrical connector from A/C pressure sensor.
2. Remove A/C pressure sensor with "O" ring from A/C refrigerant line. To install, reverse removal procedure using NEW "O" ring.

1. A/C switch is located on the heating and A/C control panel at center of instrument panel, near the stereo. Remove ash tray/cup holder and holder track located below control panel.
2. Remove control panel-to-instrument panel screws. Remove control panel from instrument panel. Disconnect wires from back of control panel. Remove control panel. To install, reverse removal procedure.

Removal

1. Remove lower cover from instrument panel for access to brake switch. Brake switch is located near top of brake pedal.
2. Depress and hold brake pedal downward. Rotate brake switch counterclockwise approximately 30 degrees and pull brake switch rearward from mounting bracket. Depress locking tabs on electrical connector and disconnect electrical connector from brake switch.

Note. Before installing brake switch, plunger on brake switch must be pulled outward to fully extended to ensure proper brake switch adjustment.

Installation

1. Pull plunger on brake switch outward to the fully extended position. Install electrical connector on brake switch. Depress brake pedal as far as possible. Install brake switch in mounting bracket. Ensure alignment tab on brake switch aligns with opening on mounting bracket. CAUTION: When adjusting brake switch, DO NOT pull brake pedal back toward brake switch with excessive pressure or brake switch may be damaged.
2. When brake switch is fully installed, rotate brake switch clockwise approximately 30 degrees. To ensure proper brake switch adjustment, gently pull brake pedal back toward brake switch as far as possible. DO NOT apply excessive pressure on brake pedal and brake switch.

1. Downstream oxygen sensor is mounted on exhaust pipe, behind catalytic converter. Raise and support vehicle. Remove grommet in floor panel to access electrical connector for downstream oxygen sensor.
2. Push locking tab backward and disconnect electrical connector for downstream oxygen sensor. Remove downstream oxygen sensor from exhaust pipe.

1. Use tap to ensure threads on exhaust pipe are clean. If installing original or used downstream oxygen sensor, apply anti-seize compound on threads of downstream oxygen sensor. A NEW downstream oxygen sensor should already be coated with anti-seize compound.
2. Install and tighten downstream oxygen sensor to specification. See TORQUE SPECIFICATIONS. Install electrical connector.

1. Drain cooling system until coolant level is below cylinder head. Disconnect electrical connector at engine coolant temperature sensor. Engine coolant temperature sensor is located near thermostat housing and contains a Black/Light Blue wire and a Tan/Black wire in the electrical connector. Remove engine coolant temperature sensor.
2. To install, reverse removal procedure. Tighten engine coolant temperature sensor to specification. See TORQUE SPECIFICATIONS. Fill cooling system.

Removal & Installation (4-Speed A/T)

1. Disconnect electrical connector from input speed sensor located on transaxle. (Scheme 31) DO NOT allow weather seal to fall from electrical connector. Unscrew input speed sensor from transaxle case. Remove seal ring from input speed sensor (if equipped).
2. To install, reverse removal procedure. Use NEW seal ring (if equipped). Tighten input speed sensor to specification. See TORQUE SPECIFICATIONS. Install electrical connector. Fill transaxle to proper level with Mopar ATF Plus Type 7176 fluid.

Scheme 31

1. Disconnect electrical connector at MAP sensor. See MAP SENSOR LOCATIONS table.
2. Disconnect vacuum hose at MAP sensor.

MAP SENSOR LOCATIONS

1. Disconnect electrical connector from output speed sensor located on transaxle. (Scheme 31) DO NOT allow weather seal to fall from electrical connector. Unscrew output speed sensor from transaxle case. Remove seal ring from output speed sensor (if equipped).
2. To install, reverse removal procedure. Use NEW seal ring (if equipped). Tighten output speed sensor to specification. See TORQUE SPECIFICATIONS. Install electrical connector. Fill transaxle to proper level with Mopar ATF Plus Type 7176 fluid.

Removal & Installation (3-Speed A/T)

1. Disconnect electrical connector from park/neutral switch located on transaxle. (Scheme 32) Unscrew park/neutral switch from transaxle case. Remove seal ring from park/neutral switch.
2. To install, apply parking brake. Move shift lever from Park to Neutral. Ensure park/neutral switch operating levers in transaxle are centered in the park/neutral switch opening on transaxle case.
3. Using NEW seal ring, install park/neutral switch. Tighten park/neutral switch to specification. See TORQUE SPECIFICATIONS. Install electrical connector. Fill transaxle to proper level with Mopar ATF Plus Type 7176 fluid.

Park/neutral switch is referred to as transmission range sensor. For servicing of transmission range sensor, see TRANSMISSION RANGE SENSOR under SENSORS & SWITCHES.

Scheme 32

1. Disconnect negative battery cable. Disconnect electrical connector from throttle position sensor mounted on side of throttle body. Remove retaining screws and throttle position sensor from throttle body.
2. To install, reverse removal procedure. Tighten retaining screws to specification. See TORQUE SPECIFICATIONS.

Removal (4-Speed A/T)

1. Valve body must be removed from transaxle for servicing of transmission range sensor. Raise and support vehicle.
2. Disconnect negative battery cable. Remove air cleaner and air intake tube. Disconnect shift cable from manual valve lever on transaxle and remove manual valve lever. (Scheme 31)
3. Disconnect electrical connector from connector for transmission range sensor. Connector for transmission range sensor is located on top of transaxle. (Scheme 31)
4. Remove bolts and oil pan from transaxle, allowing fluid to drain. Remove transaxle oil filter. Allow fluid to fully drain. Note location of valve body bolts for installation reference.
5. Remove valve body-to-transaxle case bolts. Disengage parking rod from bracket and remove valve body from transaxle. Remover retaining screw for transmission range sensor from valve body. (Scheme 33)
6. Remove manual shaft seal from manual shaft. (Scheme 33) Lift transmission range sensor from valve body and manual shaft.

1. To install, reverse removal procedure using NEW manual shaft seal. Apply RTV sealant on oil pan sealing surfaces before installing oil pan.
2. Tighten transmission range switch retaining screw, valve body-to-transaxle case bolts and oil pan bolts to specification. See TORQUE SPECIFICATIONS. Fill transaxle to proper level with Mopar ATF Plus Type 7176 fluid.

Scheme 33

Upstream oxygen sensor is mounted on exhaust manifold. Raise and support vehicle. Disconnect electrical connector for upstream oxygen sensor. Remove upstream oxygen sensor from exhaust manifold.

1. Use tap to ensure threads on exhaust manifold are clean. If installing original or used upstream oxygen sensor, apply anti-seize compound on threads of upstream oxygen sensor. A NEW upstream oxygen sensor should already be coated with anti-seize compound.
2. Install and tighten upstream oxygen sensor to specification. See TORQUE SPECIFICATIONS. Install electrical connector.

1. Vehicle speed sensor is mounted on extension housing for passenger's side axle shaft at firewall side of transaxle. (Scheme 34)
2. Disconnect electrical connector at vehicle speed sensor. Ensure area around vehicle speed sensor is clean. Remove retaining bolt and vehicle speed sensor with "O" ring from extension housing.
3. To install, reverse removal procedure using NEW "O" ring. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 34

1. Idle air control motor is mounted on the throttle body and contains a 4-pin electrical connector. Disconnect negative battery cable.
2. Disconnect electrical connector at idle air control motor. Remove retaining screws and idle air control motor with "O" ring from throttle body.

1. Install NEW "O" ring on idle air control motor. DO NOT use lubricants on "O" ring. Measure distance from end of pintle to mounting surface on idle air control motor. The pintle is the end of idle air control motor that fits into the throttle body.
2. If distance is 1" (25.4 mm) or less, go to step 4). If distance is greater than 1" (25.4 mm), pintle must be retracted before installing idle air control motor. Go to next step.
3. To retract the pintle, connect scan tool to Data Link Connector (DLC).
4. Using scan tool manufacturer's instructions to perform IDLE AIR CONTROL MOTOR OPEN/CLOSE TEST after reconnecting negative battery cable and electrical connector on idle air control motor. Once pintle is retracted, disconnect negative battery cable and electrical connector. Go to next step.
5. Install idle air control motor. Install and tighten retaining screws to specification. See TORQUE SPECIFICATIONS. Install electrical connector and negative battery cable.

Relays are located in power distribution center at driver's side front corner of engine compartment, near battery.

TCC solenoid is mounted on transaxle valve body. See appropriate AUTOMATIC TRANSMISSIONS article section.

Camshaft position sensor is located in the distributor. See DISTRIBUTOR under IGNITION SYSTEM.

1. Crankshaft position sensor is located on top of transaxle housing, above flywheel, near corner of rear exhaust manifold.
2. Raise and support vehicle. Disconnect electrical connector at crankshaft position sensor. Remove retaining bolt and crankshaft position sensor.

1. If reusing crankshaft position sensor, clean old paper spacer from crankshaft end of crankshaft position sensor. Install NEW paper spacer on crankshaft end of crankshaft position sensor. On all crankshaft position sensors, install crankshaft position sensor.
2. Push crankshaft position sensor fully downward. Install and tighten retaining bolt to specification while holding crankshaft position sensor downward. See TORQUE SPECIFICATIONS. Install electrical connector.

1. Disconnect electrical connector at side of distributor. Remove distributor cap. Rotate engine until rotor points toward intake manifold.
2. Place reference mark on distributor and intake manifold at rotor location for installation reference. Remove distributor hold-down nut. Remove distributor with "O" ring from engine.
3. To install, reverse removal procedure. Use NEW "O" ring if necessary. Ensure "O" ring is properly seated on distributor. Ensure rotor and distributor align with reference mark on intake manifold when installing distributor. Tighten distributor hold-down nut to specification. See TORQUE SPECIFICATIONS. If necessary to check firing order, see «SPECIFICATIONS - 3.0L»(ref-24743) article.

Removal & Installation (Dual Tab)

1. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Disconnect negative battery cable.
2. Ensure disconnect fitting and fuel lines are clean. Note location of tabs on disconnect fitting. (Scheme 35) Squeeze both tabs and pull disconnect fitting from fuel line. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced.
3. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until click sound is heard. CAUTION: After installing fuel line, ensure fuel line is secured in place by pulling on fuel line. If fuel line is fully seated and secured in place, shoulder on fuel line and locking ears will be visible in window on disconnect fitting.
4. Pull on fuel line and disconnect fitting to ensure components are properly locked together. When fuel line and disconnect fitting are properly locked together, shoulder on fuel line and the both locking ears will be visible in window on disconnect fitting. (Scheme 35) If shoulder and both locking ears are not visible, fuel line and disconnect fitting are not properly locked together. NOTE: Fuel leaks may be checked by starting engine or by pressurizing fuel system. Fuel system may be pressurized by using scan tool manufacturer's instructions and scan tool connected to Data Link Connector (DLC) to perform ASD FUEL SYSTEM TEST. When performing ASD FUEL SYSTEM TEST, the ASD relay and fuel pump relay remain energized for 7 minutes unless test is stopped or ignition switch is turned to OFF position.
5. Reconnect negative battery cable. Check for fuel leaks.

Removal & Installation (Plastic Retainer Ring)

1. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Disconnect negative battery cable.
2. Ensure disconnect fitting and fuel lines are clean. Note location of plastic retainer ring on disconnect fitting. (Scheme 35) NOTE: Plastic retainer ring must be pressed evenly into disconnect fitting. If plastic retainer is not even, it will be difficult to remove disconnect fitting from fuel line.
3. Firmly push disconnect fitting toward the fuel line while pushing plastic retainer ring evenly into disconnect fitting. With plastic retainer ring fully depressed, pull disconnect fitting from fuel line.
4. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced. CAUTION: After installing fuel line, ensure fuel line is secured in place by pulling on fuel line.
5. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until click sound is heard. Pull on fuel line and disconnect fitting to ensure components are properly locked together. NOTE: Fuel leaks may be checked by starting engine or by pressurizing fuel system. Fuel system may be pressurized by using scan tool manufacturer's instructions and scan tool connected to Data Link Connector (DLC) to perform ASD FUEL SYSTEM TEST. When performing ASD FUEL SYSTEM TEST, the ASD relay and fuel pump relay remain energized for 7 minutes unless test is stopped or ignition switch is turned to OFF position.
6. Reconnect negative battery cable. Check for fuel leaks.

Scheme 35

1. Fuel filter is located on top of fuel tank, near fuel pump module. (Scheme 36) Fuel lines are permanently attached to fuel filter.
2. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM.
3. Disconnect fuel lines at fuel pump module and fuel supply line using proper procedure. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM. Remove retaining bolt and fuel filter.
4. To install, reverse removal procedure. Use proper procedure for installing fuel lines. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.

Scheme 36

1. Fuel level sensor is mounted on fuel pump module. (Scheme 37)
2. Remove fuel pump module. See FUEL PUMP MODULE under FUEL SYSTEM. Depress retaining tab and disconnect electrical connector for fuel pump and fuel level sensor from electrical connector from bottom side of electrical connector mounted on top of fuel pump module.
3. Remove Blue locking wedge from inside of electrical connector for fuel pump and fuel level sensor. (Scheme 38) CAUTION: Note location of wires in electrical connector for fuel pump and fuel level sensor for installation reference. Wires must be installed in correct location.
4. Mark wire location in electrical connector for fuel pump and fuel level sensor for installation reference. Wires for fuel level sensor must be removed from the electrical connector for fuel pump and fuel level sensor.
5. Use small screwdriver to lift locking finger away from electrical terminal on the wire. Push wire with electrical terminal from electrical connector.
6. Using screwdriver, pry between fuel pump module and top of fuel level sensor to release fuel level sensor from fuel pump module. Push fuel level sensor downward, toward bottom of fuel pump module. Slide fuel level sensor from fuel pump module.

1. Install wires for fuel level sensor in bottom of fuel pump module. Place wires in groove on back side of fuel level sensor.
2. While feeding wires into guide grooves, slide fuel level sensor onto fuel pump module until fuel level sensor snaps into place. Ensure tab on fuel level sensor is fully engaged.
3. Install each wire up through electrical connector for fuel pump and fuel level sensor. Pull each wire backward until electrical terminal on the wire locks in place. Ensure wires are installed in original location.
4. Install Blue locking wedge inside electrical connector for fuel pump and fuel level sensor. Install electrical connector for fuel pump and fuel level sensor on electrical connector on bottom side of electrical connector mounted on top of fuel pump module. Reinstall fuel pump module using proper procedure.

Scheme 37

Scheme 38

1. Fuel pressure regulator is mounted on fuel pump module. (Scheme 37) Remove fuel pump module. See FUEL PUMP MODULE under FUEL SYSTEM.
2. Spread locking tabs on side of fuel pressure regulator and pry fuel pressure regulator from fuel pump module. (Scheme 37) Remove both "O" rings for fuel pressure regulator from fuel pump module.
3. To install, reverse removal procedure using NEW "O" rings lubricated with engine oil. Install "O" rings in fuel pump module before installing fuel pressure regulator. Ensure locking tabs on side of fuel pressure regulator fully engage. Reinstall fuel pump module using proper procedure.

1. Fuel pump inlet strainer is mounted on fuel pump module. (Scheme 37) Remove fuel pump module. See FUEL PUMP MODULE under FUEL SYSTEM.
2. Spread locking tabs on bottom of fuel pump module and remove fuel pump inlet strainer from fuel pump module. (Scheme 37) Remove "O" ring for end of fuel pump module.
3. To install, reverse removal procedure using NEW "O" ring lubricated with engine oil. Install "O" ring in fuel pump inlet strainer before installing fuel pump inlet strainer on fuel pump module. Ensure "O" ring sets evenly in fuel pump inlet strainer. Ensure locking tabs on fuel pump module fully engage on fuel pump inlet strainer. Reinstall fuel pump module using proper procedure.

1. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM.
2. Using siphon hose, drain gasoline from fuel tank into an approved fuel container. Raise and support vehicle. Support fuel tank with transmission jack.
3. Remove fuel tank strap bolts. Slightly lower fuel tank for access to fuel pump module. Fuel pump module is located on top of fuel tank. (Scheme 36)
4. Ensure area around fuel pump module is clean. Disconnect fuel lines at fuel pump module using proper procedure. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.
5. Push connector lock for electrical connector on fuel pump module toward the fuel lines. (Scheme 39) Push downward on retainer. (Scheme 39) Disconnect electrical connector from fuel pump module. CAUTION: When removing fuel pump module from fuel tank, use care, as reservoir on fuel pump module may still contain some gasoline.
6. Note location of fuel pump module lock nut. (Scheme 39) Using Lock Nut Wrench (6856), rotate fuel pump module lock nut counterclockwise and remove from fuel tank. Reservoir on fuel pump module may still contain some gasoline. Remove fuel pump module and "O" ring from fuel tank.

1. To install, reverse removal procedure using NEW "O" ring. Use proper procedure when installing fuel lines. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.
2. Tighten fuel pump module lock nut and fuel tank strap bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 39

1. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Remove air intake resonator assembly from top of engine and throttle body for access to air intake plenum. Air intake plenum on top of intake manifold must be removed for access to fuel rail.
2. Disconnect control cables, electrical connectors and vacuum hoses at throttle body. Disconnect connector at engine coolant temperature sensor located near thermostat housing.
3. Disconnect fuel supply line from chassis fuel supply line using proper procedure. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.
4. Remove ignition coil. Disconnect vacuum hoses from air intake plenum. Remove air intake plenum-to-intake manifold bolts. Remove air intake plenum and gasket from intake manifold. Cover intake manifold with shop towel.
5. Disconnect electrical connectors at injectors. Remove fuel rail bolts. Remove fuel rail with injectors from intake manifold. Use care not to damage "O" rings at end of injectors.
6. If removing injector from fuel rail, remove retaining clip from fuel rail and fuel injector. Pull injector from fuel rail.

1. If installing injector on fuel rail, replace "O" ring on injector if damaged. Lubricate "O" ring at top of injector with engine oil.
2. Install injector on fuel rail, using care not to damage the "O" ring. Install retaining clip. Ensure retaining clip is installed in top slot on injector.
3. To install remaining components, reverse removal procedure using NEW gaskets. Ensure injector holes are clean before installing injectors. Replace "O" ring at bottom of injector if damaged.
4. Lubricate "O" ring at bottom of injector with engine oil before installing fuel rail with injectors. Tighten fuel rail bolts to specification. See TORQUE SPECIFICATIONS.
5. Install air intake plenum gasket on intake manifold so beaded sealant area on gasket is facing upward, toward air intake plenum. Tighten air intake plenum-to-intake manifold bolts to specification, starting at the center and working outward in a crisscross pattern. See TORQUE SPECIFICATIONS.
6. Install fuel supply line on chassis fuel supply line using proper procedure and check for fuel leaks. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.

1. Disconnect negative battery cable. Remove necessary covers to access throttle body. Disconnect air intake hose, control cables, electrical connectors and vacuum hoses at throttle body. Remove bolts/nuts, throttle body and gasket.
2. To install, reverse removal procedure using NEW gasket. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS.

1. Disconnect electrical connector at EGR solenoid. Disconnect vacuum hoses from EGR valve and EGR backpressure transducer. Remove bolts, EGR valve assembly and gasket.
2. Ensure no restricted passages exist in intake manifold and EGR valve. To install, reverse removal procedure using NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

1. The EVAP purge solenoid is located near passenger's side strut tower and contains a rubber cover over outside of EVAP purge solenoid. (Scheme 40)
2. EVAP purge solenoid must be installed so the word TOP on EVAP purge solenoid is facing upward to provide proper solenoid operation. No other service information is available from manufacturer.

Scheme 40

1. Leak detection pump is located below driver's side of steering gear, above engine cradle. (Scheme 41)
2. Raise and support vehicle. Mark vacuum hose location on leak detection pump for installation reference. Disconnect electrical connector and vacuum hoses from leak detection pump. Remove bolts and leak detection pump. NOTE: Before installing vacuum hoses on leak detection pump, ensure vacuum hoses are not cracked or split. If a vacuum hose leak exists, a Diagnostic Trouble Code (DTC) will be stored in Powertrain Control Module (PCM).
3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure vacuum hoses are installed in original location and vacuum hoses are not cracked or split.

Scheme 41