This is for everyone. Add all your DIY information to share. And keep it clean.

 

What should I put on here MT?? Just common issues?

 

2001- 2007 minivan.
Codes P0404, P0405, P0406 - EGR system and sensor codes are very common and probably over 90% of the time it is the sensor in the valve that is faulty. Here is the R&R procedure for the EGR valve.

3.3/3.8L


<A xmlns="http://www.w3.org/1999/xhtml"> Fig. 1 - EGR VALVE MOUNTED

1.Disconnect and isolate negative battery cable.2.Remove accessory drive belt.3.Remove generator mounting bolts and reposition generator.4.Unlock and disconnect the electrical connector from the EGR valve.5.Remove the 2 EGR tube bolts.


<A xmlns="http://www.w3.org/1999/xhtml"> Fig. 2 - EGR VALVE GASKET

6.Remove the 2 mounting bolts for the EGR valve and gasket.

Installation

3.3/3.8L


<A xmlns="http://www.w3.org/1999/xhtml"> Fig. 1 - EGR VALVE GASKET

1.Install a new gasket on the EGR valve.


<A xmlns="http://www.w3.org/1999/xhtml"> Fig. 2 - EGR VALVE MOUNTED

2.Position EGR valve to cylinder head and install the 2 mounting bolts.3.Tighten EGR valve mounting bolts to 31 N·m (23 ft. lbs.).4.Position EGR tube to EGR valve and install the 2 mounting bolts.5.Tighten EGR tube mounting bolts to 13 N·m (115 in. lbs.).6.Connect electrical connector to EGR valve.7.Install generator mounting bolts.8.Install accessory drive belt.9.Connect negative battery cable.

When I do these, I do not remove the altenator. 9 out of 10 you can sneak the bolt on the bottom out without removing it. If it needs to be moved, I remove the top and front bolt and pry the altenator out enough to access the bolt.

 

I see alot of posts for the RS minivan ('01 - '07) for blower motor only has high or doesn't work at all. The blower motor in these vans sit directly below the fresh air intake. When it rains or you go through the car wash, water gets in on the blower motor. Over time, the bushings stiffen up and it takes more power to get the motor to start to turn. When it gets bad enough, the resistor will fail and you can get either condition. You can just replace the resistor but eventually you will also have to replace the blower motor. Here is a wiring diagram (this one is '04 but all are similar) for the blower motor and resistor for a manual temp control.

 

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

WARNING: THE BLOWER MOTOR RESISTOR MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTOR TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN PERSONAL INJURY.

CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage.

Disconnect and isolate the battery negative cable.
Open the glove box.
Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box downward.
Reach through the glove box opening to access and disconnect the instrument panel wire harness connector for the blower motor resistor from the resistor connector receptacle (Blower Motor Resistor).
Reach through the glove box opening to access and disconnect the blower motor pigtail wire connector from the resistor connector receptacle.
Remove the two screws that secure the blower motor resistor to the evaporator housing.
Remove the blower motor resistor from the evaporator housing.
For 2001 to 2007 RS

 

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

WARNING: THE BLOWER MOTOR RESISTOR MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTOR TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN PERSONAL INJURY.

CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage.

Disconnect and isolate the battery negative cable.
Open the glove box.
Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box downward.
Reach through the glove box opening to access and disconnect the instrument panel wire harness connector for the blower motor resistor from the resistor connector receptacle (Blower Motor Resistor).
Reach through the glove box opening to access and disconnect the blower motor pigtail wire connector from the resistor connector receptacle.
Remove the two screws that secure the blower motor resistor to the evaporator housing.
Remove the blower motor resistor from the evaporator housing.
For 2008 to 2010 RT Body

 

ACTUATOR CALIBRATION/DIAGNOSTICS AND COOLDOWN TEST
GENERAL INFORMATION
If the HVAC control module is replaced, the Calibration Diagnostic and Cooldown tests will need to be performed. Once this group of tests have successfully passed, they can be performed individually. The engine must be running during the test to provide hot coolant for the heater, A/C compressor operation and to assure that the actuators are calibrated correctly. The HVAC control module is capable of troubleshooting the system in approximately 120 seconds. If a condition is detected, an error code is displayed. The error code cannot be erased until the condition is repaired and the diagnostic test is performed. Check wire before replacing components, Refer to Wiring Diagrams.

CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied. Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out of calibration.

ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the actuators, HVAC control module and its linkages. In-vehicle calibration can be entered from the control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a failure occurred Radio Bezel and HVAC Control and Radio Bezel and HVAC Control, Rear Blower Motor Switch and Zone Control Diagnostics will always occur during Calibration Diagnostic and Cooldown test.

DIAGNOSTICS
During the Actuator calibration, diagnostics are performed on the actuators and evaporator temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT LED's will flash to indicate either a successful calibration or the appropriate fail code(s) At this time manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash simultaneously showing that a failure has occurred. The control will not indicate the fail code, but only that a failure had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the Calibration Diagnostic and Cooldown test, after all repairs are completed.

COOLDOWN TEST
This test has been designed for performance testing of the A/C system at the manufacturing facility. If the HVAC control module is replaced, the Cooldown test will occur during Calibration test. Cooldown will not occur on Heater Only units. During the Cooldown test the control will monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature down a predetermined minimum amount in less than 2 minutes.

CALIBRATION/COOLDOWN LED DISPLAY CODES
See chart for definition of flashing LED's. If no problems are found, the control functions normally.

LED'S PASS/FAIL CORRECTIVE ACTION
NO LED'S FLASHING-NORMAL OPERATION PASSED CALIBRATION, DIAGNOSTICS AND COOLDOWN NONE
REAR WIPER AND INTERMITTENT LED'S FLASH SIMULTANEOUSLY FAILED CALIBRATION DIAGNOSTICS RUN CALIBRATION TEST
A/C AND RECIRC LED'S FLASH SIMULTANEOUSLY FAILED COOLDOWN RUN COOLDOWN TEST
REAR WIPER AND INTERMITTENT LED'S ARE FLASHING SIMULTANEOUSLY A/C AND RECIRC LED'S ARE FLASHING SIMULTANEOUSLY FAILED CALIBRATION, DIAGNOSTICS AND FAILED COOLDOWN TEST RUN CALIBRATION TEST

CALIBRATION/DIAGNOSTICS TEST ENTRY
TO INITIATE TESTS:
Set Blower motor ON HIGH
Set Mode position to Panel
Open all A/C outlets
Set Temperature to Cold (Both slide pots if equipped)
Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LED's light)
RESULTS:
All LED's will turn on for 5 Seconds
Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing. Cooldown test is running if A/C and RECIRC are alternately flashing.
Acceptable results is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit.
After all tests have passed, Calibration Diagnostics and Cooldown can be run separately.
COOLDOWN TEST ENTRY
TO INITIATE TESTS:
Set Blower motor ON HIGH
Set Mode position to Panel
Open all A/C outlets
Set Temperature to Cold (Both slide pots if equipped)
Depress WASH and A/C simultaneously for 5 Seconds
NOTE: Prior to start of test, If the evaporator is already cold, the system will fail test. To correct, operate system with A/C OFF and the blower motor ON high for three minutes prior to starting test.

RESULTS:
All LED's will turn on for 5 Seconds
Cooldown Test is running when A/C and RECIRC. are alternately flashing. If A/C and RECIRC. are flashing simultaneously, Cooldown has failed.
CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT
Test can be aborted by doing one of the following:

Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons.
Cycling Ignition OFF and then ON.
Control will automatically abort after 15 minutes from the time Calibration Diagnostics and Cooldown was entered.
The HVAC control module will return to normal operation or may indicate unsuccessful Calibration Diagnostics or Cooldown test by LED's flashing simultaneously.

EEPROM DATA
Calibration Diagnostics, Cooldown Status and evaporator temperature Fin Sensor values are stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control module uses this information:

To determine if Cooldown needs to run
For proper position of the Heater-A/C unit assembly doors
ACTUATOR CALIBRATION AND DIAGNOSTICS
NOTE: Do not run actuators unless they are properly mounted on the HVAC control module.

Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as actuator travel falling within their minimum and maximum limits.

BLEND/PASSENGER ACTUATOR BACKGROUND
The Blend/Passenger Actuator can move the temperature door in two directions. When the voltage at Pin 12 of the control module is high, about 11.5 volts, and the voltage at Pin 17 is low, about 1.5 volts, the door will move towards the Heat position. When Pin 17 is High and Pin 12 is Low the door will move towards the Cold position. When both Pins are high or both Pins are low, the actuator will not move. The Blend/Passenger feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Blend/Passenger actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door.

DRIVER ACTUATOR BACKGROUND
The Driver Actuator can move the temperature door in two directions. When the voltage at Pin 15 of the control module is high, about 11.5 volts, and the voltage at Pin 13 is low, about 1.5 volts the door will move towards the Cold position. When Pin 13 is High and Pin 15 is Low the door will move towards the Heat position. When both Pins are high or when both Pins are low, the actuator will not move. The Driver feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Driver Actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door.

MODE ACTUATOR BACKGROUND
The Mode actuator can move the mode door in two directions. When the voltage at Pin 18 of the control module is high, about 11.5 volts, and the voltage at Pin 12 is low, about 1.5 volts the door will move towards the Panel position. When Pin 12 is High and Pin 18 is Low the door will move towards the Defrost position. When both Pin are high or when both Pins are low, the actuator will not move. The Mode door feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.5 volts in the Panel position and 0.5 volts in the Defrost position. As the position of the Mode actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the mode door.

FAIL CODES/LEVEL DISPLAY
Fail Codes/Level are displayed using the REAR WIPER and INTERMITTENT LED's flashing in the sequence indicated below. The REAR WIPER LED represents the Level and the INTERMITTENT LED represents the Value. After Calibration/Diagnostics is completed, the control will begin flashing Level 1 codes. Depressing the WASH button will cycle to Level 2, depressing WASH again will cycle to Level 3. Each time the WASH button is depressed will cycle to the next level. After Level 5 is reached, you will cycle back to Level 1. If the Control is a Heater Only you will only cycle from Levels 1 to 3.

WIPE BUTTON LED
LEVEL DISPLAY
1 FAIL CODES
2 MODE POTENTIOMETER TEST
3 BLEND/PASS. POTENTIOMETER TEST
4 EVAPORATOR PROBE (A/C AND ZONE UNITS ONLY)
5 DRIVER POTENTIOMETER (ZONE UNITS ONLY)

LEVEL 1 - FAILURE CODE VALUES (INTERMITTENT WIPE BUTTON LED)
CODE DEFINITION
0 PASSED ALL TESTS
1 MODE ACTUATOR DID NOT REACH DEFROST POSITION
2 MODE ACTUATOR DID NOT REACH PANEL POSITION
3 BLEND/PASS. ACTUATOR DID NOT REACH COLD STOP
4 BLEND PASS. ACTUATOR DID NOT REACH HEAT STOP
5 EVAPORATOR PROBE OPEN
6 EVAPORATOR PROBE SHORTED
7 DRIVER ACTUATOR DID NOT REACH COLD STOP
8 ZONE/DRIVER ACTUATOR DID NOT REACH HEAT STOP
9 CONTROL HEAD INTERNAL FAILURE

TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS
The Temperature and Mode Potentiometer can be tested after calibration is complete by pressing the WASH button and cycling to Levels 2, 3 or 5 as displayed by the REAR WIPER LED. On Heater Only units you can only cycle to Levels 2 and 3. In each individual test the INTERMITTENT LED flash rate will change as the Temperature or Mode potentiometer is moved from one end to the other, see Potentiometer vs. Position and Flash Rate table.

POTENTIOMETER vs. POSITION AND FLASH RATE
POTENTIOMETER INTERMITTENT LED FASTER FLASH RATE INTERMITTENT LED SLOWER FLASH RATE
MODE PANEL DEFROST
BLEND/PASS. HOT COLD
DRIVER HOT COLD

EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following:

Set Blower motor to any speed other than OFF
Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds.
Run Diagnostics (Depress REAR WIPER and REAR WASH)
When Diagnostics is complete, Cycle to Level 4.
Display Sequence is as follows:

REAR WIPER LED will display the Level
INTERMITTENT LED will display ten's digit
Short Pause
INTERMITTENT LED will display the one's digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cooldown test is exited.

 

3.0L ENGINE
DESCRIPTION
The 3.0 Liter (181 cu. in.) 60° V-6 engine is a single overhead camshaft (per bank) design 3.0L Engine . The engine does have free-wheeling valve train.

The firing order is 1 - 2 - 3 - 4 - 5 - 6. The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, and 6. The rear cylinder bank is numbered 1, 3, and 5.

The engine identification number is located on the rear of the cylinder block just below the cylinder head Engine Identification .

 

DESCRIPTION
Two refrigerant system service ports are used to recover/recycle/evacuate/charge and test the A/C refrigerant system. Unique sizes are used on the service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or service equipment used for R-12 refrigerant.

The high side service port is located on the A/C liquid line near the front of the right front wheel well. The low side service port is located on the A/C suction line near the A/C expansion valve at the dash panel. Both the high side and low side A/C service port valve cores are serviceable.

Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps.

 

HYDRAULIC PRESSURE TESTS
Pressure testing is a very important step in the diagnostic procedure. These tests usually reveal the cause of most transaxle problems.

Before performing pressure tests, check fluid level and condition, as well as control cable adjustments. Fluid must be at operating temperature (150 to 200 degrees F.)

Install an engine tachometer. Raise vehicle on a hoist that allows front wheels to turn, and position tachometer so it can be read.

Disconnect throttle cable and shift cable from transaxle levers so they can be controlled from outside the vehicle.

Attach 150 psi gauges to ports required for test being conducted. A 300 psi gauge (C-3293) is required for reverse pressure test at rear servo.

Test port locations are shown in


Test Port Locations
TEST ONE (SELECTOR IN 1)
Attach gauges to line and low-reverse ports.
Operate engine at 1000 rpm for test.
Move selector lever on transaxle all the way rearward (1 position)
Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterclockwise position.
Line pressure should read 52 to 58 psi with throttle lever clockwise. Pressure should gradually increase to 80 to 88 psi.as lever is moved counterclockwise.
Low/reverse pressure should read the same as line pressure, within 3 psi.
This tests pump output, pressure regulation, and condition of rear clutch and rear servo hydraulic circuits.
TEST TWO (SELECTOR IN 2)
Attach one gauge to line pressure port, and tee another gauge into lower cooler line fitting. This will allow lubrication pressure readings to be taken.
Operate engine at 1000 rpm for test.
Move selector lever on transaxle one detent forward from full rearward position. This is selector 2 position.
Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterclockwise position.
Line pressure should read 52 to 58 psi with throttle lever clockwise. Pressure should gradually increase to 80 to 88 psi. as lever is moved counterclockwise.
Lubrication pressure should be 10 to 25 psi with lever clockwise and 10 to 35 psi with lever at full counterclockwise.
This tests pump output, pressure regulation, and condition of rear clutch and lubrication hydraulic circuits.
TEST THREE (SELECTOR IN D)
Attach gauges to line and kickdown release ports.
Operate engine at 1600 rpm for test.
Move selector lever on transaxle two detents forward from full rearward position. This is selector D position.
Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise to the full counterclockwise position.
Line pressure should read 52 to 58 psi with throttle lever clockwise. Pressure should gradually increase to 80 to 88 psi. as lever is moved counterclockwise.
Kickdown release is pressurized only in direct drive and should be same as line pressure within 3 psi, up to kickdown point.
This tests pump output, pressure regulation, and condition of rear clutch, front clutch, and hydraulic circuits.
TEST FOUR (SELECTOR IN REVERSE)
Attach 300 psi gauge to low-reverse port.
Operate engine at 1600 rpm for test.
Move selector lever on transaxle four detents forward from full rearward position. This is selector R position.
Low/reverse pressure should read 180 to 220 psi with throttle lever clockwise. Pressure should gradually increase to 260 to 300 psi. as lever is moved counterclockwise.
This tests pump output, pressure regulation, and condition of front clutch and rear servo hydraulic circuits.
Move selector lever on transaxle to D position to check that low/reverse pressure drops to zero.
This tests for leakage into rear servo, due to case porosity, which can cause reverse band burn out.
TEST RESULT INDICATIONS
If proper line pressure, minimum to maximum, is found in any one test, the pump and pressure regulator are working properly.
Low pressure in D, 1, and 2 but correct pressure in R, indicates rear clutch circuit leakage.
Low pressure in D and R, but correct pressure in 1 indicates front clutch circuit leakage.
Low pressure in R and 1, but correct pressure in 2 indicates rear servo circuit leakage.
Low line pressure in all positions indicates a defective pump, a clogged filter, or a stuck pressure regulator valve.
GOVERNOR PRESSURE
Test only if transaxle shifts at wrong vehicle speeds when throttle cable is correctly adjusted.

Connect a 0-150 psi pressure gauge to governor pressure take-off point. It is located at lower right side of case, below differential cover.
Operate transaxle in third gear to read pressures. The governor pressure should respond smoothly to changes in mph and should return to 0 to 3 psi when vehicle is stopped. High pressure (above 3 psi) at standstill will prevent the transaxle from downshifting.
THROTTLE PRESSURE
No gauge port is provided for throttle pressure. Incorrect throttle pressure should be suspected if part throttle upshift speeds are either delayed or occur too early in relation to vehicle speed. Engine runaway on shifts can also be an indicator of low throttle pressure setting, or misadjusted throttle cable.

In no case should throttle pressure be adjusted until the transaxle throttle cable adjustment has been verified to be correct.
This is for the 31TH transmission