Electronic Control Modules: Removal & Installation Dodge Caravan IV

REMOVAL

1. Disconnect and isolate the battery negative cable.
2. Remove the lower instrument panel silencer.
3. Remove the knee blocker and reinforcement «(Refer to BODY/INSTRUMENT PANEL/KNEE BLOCKER REINFORCEMENT - REMOVAL)»(ref-248887-S31163616442007022700000) .
4. Disconnect the five wire connectors from the bottom of the Body Control Module (BCM).
5. Move bulkhead wiring aside.
6. Remove the screws holding the BCM to the bulkhead.
7. Remove the BCM from the mounting bracket.

INSTALLATION

1. Install the BCM to the mounting bracket.
2. Install the screws holding the BCM to the bulkhead.
3. Connect the five wire connectors to the bottom of the Body Control Module (BCM).
4. Install the knee blocker and reinforcement «(Refer to BODY/INSTRUMENT PANEL/KNEE BLOCKER REINFORCEMENT - INSTALLATION)»(ref-248887-S28875990042007022700000) .
5. Install the lower instrument panel silencer.
6. Connect the battery negative cable.
7. Verify proper operation of BCM and its functions.

1. Slide the CAB onto the HCU. see scheme 11
2. Install screws securing the CAB to the HCU Tighten the mounting screws to 2 N.m (17 in lbs). see scheme 11
3. Reconnect the 24-way wiring connector and the pump/motor wiring connector. see scheme 10
4. Install the battery tray «(Refer to ELECTRICAL/BATTERY SYSTEM/TRAY - INSTALLATION)»(ref-248889-S09169896022007022700000).
5. Install the screw securing the coolant filler neck to the battery tray.
6. Reconnect the vacuum hose to the coolant tank built into the battery tray.
7. Install the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(ref-248889-S17951773902007022700000).
8. Reconnect the battery cables.
9. Connect a DRBIII(R) to the vehicle. Check and clear any faults, and initialize the system.

Note. Front Control Module must be programmed to the correct radio EQ curve using the DRB III(R). This will ensure that the audio system is operating correctly.

1. Install the Front Control Module (FCM) in the Integrated Power Module (IPM) assembly by pushing the 49-way electrical connector straight in.
2. Install the FCM retaining screws. Torque the screws to 1 N.m (7 in. lbs).
3. Rotate the IPM assembly downward to secure in mounting bracket.
4. Install the battery in the vehicle. Refer to the procedure in «BATTERY SYSTEM»(ref-248889) .
5. Connect the positive and negative battery cables.
6. Using the DRB III(R), under "FRONT CONTROL MODULE" then "MISC" program the EQ curve of the radio into the Front Control Module. Refer to «BODY DIAGNOSTIC PROCEDURES»(ref-247598) .

Note. If the vehicle is not equipped with Name Brand Speakers (Infinity, etc.) or Headlamp Washers the DRB III(R) must be used to Disable the appropriate relays in the Integrated Power Module Assembly.

1. Disconnect and isolate the negative battery cable.
2. Remove the appropriate front seat from the vehicle «(Refer to BODY/SEATS/SEAT - REMOVAL)»(ref-248887-S15246725242007022700000) .
3. Unsnap the module from the seat cushion pan.
4. Disconnect the module wire harness connectors.

1. Connect the module wire harness connectors.
2. Snap the module on the seat cushion pan.
3. Install the appropriate front seat in the vehicle «(Refer to BODY/SEATS/SEAT - INSTALLATION)»(ref-248887-S35486064762007022700000) .
4. Connect and isolate the negative battery cable.

1. Disconnect and isolate the battery negative cable.
2. Remove the driver side front bucket seat retaining nuts from under the vehicle «(Refer to BODY/SEATS/SEAT - REMOVAL)»(ref-248887-S15246725242007022700000) .
3. Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat.
4. Disconnect the memory seat/mirror module electrical connectors. Depress the retaining tab and pull straight apart.
5. Remove the module retaining bolts and remove the module from the bracket.

1. Position and install the module retaining bolts.
2. Connect the memory seat/mirror module electrical connectors.
3. Position the drivers seat in the mounting holes in the floor pan.
4. Install the driver side front bucket seat retaining nuts from under the vehicle «(Refer to BODY/SEATS/SEAT - INSTALLATION)»(ref-248887-S35486064762007022700000) .
5. Connect the battery negative cable.

Scheme 5

Vehicles equipped with a power liftgate (PLG) utilize a PLG control module. This module is located on the vehicles left side D-pillar just below the motor assembly and contains a microprocessor, which is used to communicate to the vehicles body control module. The PLG control module receives and monitors logic inputs from all the PLG system switches except for the outside handle switch. This module also contains the software technology to detect liftgate obstructions and stop and/or reverse the door accordingly. (Scheme 5)

1. Disconnect and isolate the battery negative cable.
2. Remove the left D-pillar trim panel from the vehicle. «(Refer to BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL - REMOVAL)»(ref-248887-S29903520132007022700000)
3. Disconnect the wire harness connections from the power liftgate motor assembly.
4. Remove the screw holding the power liftgate control module to the D-pillar. see scheme 16
5. Remove the power liftgate control module from the vehicle.

1. Install the Power Liftgate (PLG) control module on the D-pillar and install retaining screw.
2. Connect the wire harness connections to the PLG control module. Be certain to slide connector locks to the locked position.
3. Install the D-pillar trim panel on the vehicle. «(Refer to BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL - INSTALLATION)»(ref-248887-S09343472772007022700000)
4. Connect the battery negative cable.
5. Using an appropriate scan tool, check and erase any PLG control module diagnostic trouble codes.
6. Verify PLG system operation. Cycle the PLG through one complete open and close cycle, this will allow the PLG control module to relearn its cycle with the new components.

REMOVAL - NGC CONTROLLER

The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a Diagnostic Trouble Code (DTC) may be set. Refer to POWERTRAIN DIAGNOSTIC PROCEDURES and the DRBIII(R) scan tool.

Scheme 6

Scheme 7

Scheme 8

1. Turn wheels to the left.
2. Disconnect the negative battery cable.
3. Raise vehicle and support.
4. Remove the left front wheel well splash shield. (Scheme 7)
5. Unlock and disconnect the electrical connectors. (Scheme 8)
6. Remove 3 screws from PCM to mounting bracket.
7. Remove the PCM.

INSTALLATION - SBEC CONTROLLER

1. Install the PCM.
2. Install the lower PCM mounting bolt. Tighten bolt.
3. Install the 2 upper PCM bracket bolts. Tighten bolt.
4. Install the headlamp, refer to «HEADLAMP»(ref-248898-S38083358702007022700000) for more information.
5. Install the 2 PCM connectors.
6. Install the battery shield, refer to «BATTERY SYSTEM»(ref-248889) for more information.
7. Connect the negative battery cable.

The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a diagnostic trouble code (DTC) may be set and SKIM must be done or car will not start if it is a SKIM equipped car. If a SKIM car you must do a secret key transfer also. Refer to POWERTRAIN DIAGNOSTIC PROCEDURES and the DRBIII(R) scan tool.

1. Install PCM module to the mounting bracket.
2. Install electrical connectors and lock.
3. Install the splash shield.
4. Lower vehicle.
5. Connect the negative battery cable.
6. Using DRBIII(R) scan tool, program mileage and vehicle identification number (VIN) into PCM. Refer to the DRBIII(R) scan tool and «POWERTRAIN DIAGNOSTIC PROCEDURES»(ref-247595) .

Scheme 9

Vehicles equipped with a power sliding door system utilize a sliding door control module. The sliding door control module is located behind the sliding door trim panel in the center of the door, just above the sliding door motor. (Scheme 9) This module controls the operation of the door through the Programmable Communication Interface (PCI) data bus circuit and the Body Control Module (BCM). The sliding door control module contains software technology which enables it to detect resistance to door travel and to reverse door travel in order to avoid damage to the door or to avoid possible personal injury if the obstruction is a person. This feature functions in both the opening and closing cycles. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB III(R) is required to read and troubleshoot these trouble codes. The sliding door control module can be reflashed if necessary. Refer to the latest Technical Service Bulletin (TSB) Information for any updates.

The power door control module is a replaceable component and cannot be repaired, if found to be faulty it must be replaced.

1. Disconnect and isolate the battery negative cable.
2. Remove the appropriate door trim panel from the vehicle. «(Refer to BODY/DOORS - SLIDING/TRIM PANEL - REMOVAL)»(ref-248887-S31016143102007022700000)
3. Remove the weather shield.
4. Disconnect the power door control module electrical connectors. Slide the red locking tab out (away from module) and depress connector retaining tab, while pulling straight apart. 1 - SLIDING DOOR CONTROL MODULE 2 - MODULE RETAINING SCREW 3 - MODULE ELECTRICAL CONNECTORS 4 - DOOR MOTOR ASSEMBLY 5 - FLEX DRIVE ASSEMBLY 6 - DOOR MOTOR RETAINING FASTENERS 7 - DOOR MOTOR ELECTRICAL CONNECTOR
5. Remove the control module retaining screw. see scheme 25
6. Remove the module from the vehicle.

1. Position the sliding door control module and install the retaining screw.
2. Connect the electrical connectors. Slide the locking tab into the locked position.
3. Install the weather shield.
4. Install the appropriate door trim panel on the vehicle. «(Refer to BODY/DOORS - SLIDING/TRIM PANEL - INSTALLATION)»(ref-248887-S16090191372007022700000)
5. Connect the battery negative cable.
6. Using an appropriate scan tool, check and erase any power door control module diagnostic trouble codes.
7. Verify power door system operation. Cycle the power door through one complete open and close cycle.