I have a 1998 Caravan that has a re-occurring P1491 code. I have changed the relay 3 times, replaced the connector with a new pigtail, cleaned and used heat-sink compound on the new relays, Gray wire has 12volts, fans have been replaced, and checked with a jumper from the grey to green wire. The fans do work in the bypass test.

New relay works anywhere from 3 days to 3 months. This time around the fans would not come on again. I pulled the relay rechecked the new pigtail connections to make sure one did not come loose, plugged the relay back in and the fans now come on with the ignition off and will not stop unless you unplug the relay or disconnect the battery.

Is this a PCM problem or am i just missing something really simple?

Any help would be great. Is there a multimeter test to verify a bad relay?

 

Welcome to DF
Have you had the recall 771 yet?



No. 771
May, 1998

To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification #771 -- Radiator Fan Relay and Reprogram Powertrain Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through:
• November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position)
• December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)

The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed).

Each parts package contains the following components:

Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label, Authorized Modifications



Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed.

Service Procedure
Replace Radiator Fan Relay:
With the ignition key in the OFF position, disconnect the battery.
Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.

Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
Remove the air cleaner housing.
Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator.
Disconnect the radiator fan relay wiring connector.
Remove the radiator fan relay. Discard the relay and the attaching screws.
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 provided screws.

Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
Install the air cleaner housing.
Install the resonator assembly and connect the upper and lower air inlet hoses.
Install the resonator to upper radiator support screws. Tighten the screws securely.
Connect the negative battery cable.
Reprogram the PCM:
Connect the MDS (Mopar Diagnostic System) and the DRB III® (Scan Tool) to the vehicle and power them up.
NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.

Use the arrow keys and select #2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.
Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU.
Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM.
The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.
NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D.

The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process.
Install Authorized Software Update Label:
Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label.
Install the Authorized Modification Label:
Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label.
IMPORTANT
DEALER SERVICE INSTRUCTIONS
Customer Satisfaction Notification #771
Radiator Fan Relay and Reprogram PCM
This service requirement applies only to 1998 model year Dodge Caravan and GrandCaravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position)
December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed).


CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE’S RADIATOR FAN RELAY AND REPROGRAM THE POWERTRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:

The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service.

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 the engine to overheat.
What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one 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 to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment.

• Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer.

If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.

 

Thanks for the reply. I looked on The Dodge site and they say that the van is not under a recall. I'm going to call the dealer tomorrow and see if i can get this fixed. If not would replacing the PCM be the next step along with a new relay?