 Copyright 2005, DaimlerChrysler Corporation, All Rights Reserved
January 2005
Dealer Service Instructions for:
Safety Recall D48 – Radio Vent Slots
2001-2002 (RS) Dodge Caravan/Grand Caravan and Chrysler Voyager and
Town & Country
NOTE: This recall applies only to the above vehicles equipped with a base radio
system (Sales Code RAS) built after April 26, 2001 (MDH 0426XX).
Moisture from the air conditioning ducts may enter into the radio on about 238,000
of the above vehicles. This can cause a short circuit and result in a left rear
speaker fire.
Vent slots on the top of the radio must be covered to prevent moisture from
entering into the radio.
Models
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle
inventory. Dealers should complete this recall service on these vehicles before
retail delivery. Dealers should also perform this recall on vehicles in for service.
Involved vehicles can be determined by using the VIP inquiry process.
Subject
Repair
Safety Recall D48 – Radio Vent Slots Page 2
Part Number Description
CBRND480 Aluminum Foil Tape Package
Each package contains two (2) pieces of aluminum foil conductive tape.
Each dealer to whom vehicles in the recall were invoiced will receive enough Foil
Tape Packages to service about 10% of those vehicles.
1. Remove the screw access cover
from the bottom of the
instrument panel center stack
bezel (Figure 1).
2. Remove the center bezel
attaching screws (Figure 1).
3. Gently pry out on the edge of the
instrument panel center bezel
using a trim stick (special tool
#C-4755 or equivalent). Set the
bezel aside leaving the accessory
switches connected.
4. Clean the top of the radio
assembly with a clean cloth.
Parts Information
Service Procedure
Figure 1
CENTER
STACK
BEZEL
“RAS”
RADIO
BEZEL
SCREWS
Safety Recall D48 – Radio Vent Slots Page 3
5. Peel the paper backing from the
supplied aluminum foil tape
strips and apply the tape strips
to the top of the radio so that the
two rows of vent slots are
covered (Figure 2). Be sure that
the slots are completely covered
and that the tape is sealed
around all of the edges.
6. Install the instrument panel
center bezel (Figure 1). Install
the bezel retaining screws and
tighten them securely.
7. Install the screw access cover at
the bottom of the center bezel.
Service Procedure (Continued)
Figure 2
Safety Recall D48 – Radio Vent Slots Page 4
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims
submitted will be used by DaimlerChrysler to record recall service completions
and provide dealer payments.
Use the following labor operation number and time allowance:
Labor Operation Time
Number Allowance
Install foil tape over radio vent slots 08-D4-81-82 0.2 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.
All dealers will receive a copy of this dealer recall notification letter by mail. Two
additional copies will be sent through the DCMMS. This notification can be
viewed on DealerCONNECT by selecting “Global Recall System” on the Service
tab, then clicking on the description of this notification or by selecting
TechCONNECT and “Search Bulletins/Recalls.”
All involved vehicle owners known to DaimlerChrysler are being notified of the
service requirement by first class mail. They are requested to schedule appointments
for this service with their dealers. A generic copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification postcard to allow owners
to update our records if applicable.
Dealers are encouraged to consider alternative scheduling and servicing approaches
for this recall. This repair does not require hoists or other full service facility special
equipment and is a DaimlerChrysler Mobile Service approved repair.
Completion Reporting and Reimbursement
Dealer Notification
Owner Notification and Service Scheduling
Safety Recall D48 – Radio Vent Slots Page 5
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer
recall notification letter.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that
was obtained from the Department of Motor Vehicles of various states. Use of this information
is permitted for this recall only and is strictly prohibited from all other use.
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Services Field Operations
DaimlerChrysler Corporation
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
Additional Information
SAFETY RECALL – RADIO VENT SLOTS
Dear: (Name)
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
DaimlerChrysler Corporation has decided that a defect, which relates to motor vehicle safety, exists in
some 2001 and 2002 model year Dodge Caravan/Grand Caravan and Chrysler Voyager and Town
& Country minivans equipped with the standard (base) radio system.
The problem is... Moisture from the air conditioning ducts may enter into the radio on your
minivan (VIN: xxxxxxxxxxxxxxxxx). This can cause a short circuit and result in
a left rear speaker fire.
What your dealer
will do...
DaimlerChrysler will repair your minivan free of charge (parts and labor). To
do this, your dealer will cover the radio vent slots to prevent moisture intrusion. The
work will take about ½ hour to complete. However, additional time may be
necessary depending on how dealer appointments are scheduled and processed.
What you must
do to ensure your
safety...
Simply contact your dealer right away to schedule a service appointment. Ask the
dealer to hold the parts for your vehicle or to order them before your appointment.
Remember to bring this letter with you to your dealer.
If you need
help...
If you have questions or concerns which your dealer is unable to resolve, please
contact DaimlerChrysler at 1-800-853-1403.
Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions
listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN
(VVVVVVVV) and notification code D48 on the postcard.
If you have already experienced this condition and have paid to have it repaired, you may send your
original receipts and/or other adequate proof of payment to the following address for reimbursement:
DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement.
If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you
may submit a written complaint to the Administrator, National Highway Traffic Safety Administration,
400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Auto Safety Hotline at
1-888-327-4236.
We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your
attention to this important matter.
Customer Services Field Operations
DaimlerChrysler Corporation
Notification Code D48
Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

 

08 - Electrical / 8M - Message Systems / Overhead Console/Diagnosis and Testing
OVERHEAD CONSOLE
Any diagnosis of the overhead console should begin with the use of a diagnostic scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Procedures information.

If the problem with the overhead console is an inaccurate or dashed (- -) display, refer to SELF-DIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper diagnostic procedures information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedures.

Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Refer to the appropriate wiring information.

1. Check the fused B(+) fuse in the integrated power module. If OK, go to Step #2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
2. Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step #3. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required.
3. Check the fused ignition switch output (run/start) fuse in the integrated power module. If OK, go to Step #4. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the integrated power module. If OK, go to Step #5. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required.
5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavity of the roof wire harness connector for the electronics module and a good ground. There should be continuity. If OK, go to Step #6. If not OK, repair the open ground circuit as required.
6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the roof wire harness connector for the electronics module. If OK, go to Step #7. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required.
7. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the electronics module. If OK, refer to SELF-DIAGNOSTIC TEST. If not OK, repair the open fused ignition switch output (run/start) circuit to the fuse in the integrated power module as required.


SELF-DIAGNOSTIC TEST
A self-diagnostic test is used to determine that the electronics module is operating properly, and that all the PCI data bus messages are being received for initial operation. Initiate the self-diagnostic test as follows:

1. With the ignition switch in the Off position, on Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles simultaneously depress and hold the STEP and the RESET buttons. On Compass Temperature Module (CT) equipped vehicles depress the C/T and the US/M push buttons.
2. Turn the ignition switch to the On position.
3. Following completion of these tests, the electronics module will display one of the following messages:
Pass Self Test (EVIC only), PASS (CT, CMTC) - The electronics module is working properly.
Failed Self Test (EVIC only), FAIL (CT, CMTC) - The electronics module has an internal failure. The electronics module is faulty and must be replaced.



NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. (Refer to 08 - Electrical/Overhead Console - Standard Procedure) .

NOTE: If the compass reading display is blank and only “CAL” appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. (Refer to 08 - Electrical/Overhead Console - Standard Procedure) .

 

Excellent instructions! I would emphasize using heavy-duty wiper arm pullers like the ones described in these descriptions. I've removed the arms on 2003 & 2006 GCs, and they were a total b*tch to get off. I had originally used a lighter-duty (cheapo?) puller, but when the turn-handle started to bend, that should have been the immediate clue that I needed something more heavy-duty. After the arms came off, it's ten minutes max to get the rest of the wiper cowl off. (I did this to get at the three spark plugs on the firewall side of the engine.)

Thanks trophyslayer!

 

There something else that works to. And that is battery post removal tool. I use this a lot too. Or channel lock pliars

 

I try to make this easy for everyone, You need to replace the brake parts thats on the extented warranty. You can not use aftermarket parts at all. Warranty on brakes are 12 months or 12k, But with the extented warranty from 12k to 24k your deductable will 50.00 dollars and from 24k to 36k it will be 100.00 dollars. But you need to have the campaign part numbers on the the vehicle. I hope this helps, and i will post the TSB too.



SUBJECT:
Vibration At The Front Of The Vehicle When Braking And/Or Front Brake Pad Lining Life
(Warranty Extension)
OVERVIEW:
This bulletin involves installing new brake linings and replacing both brake rotors as
required.
MODELS:
2009-2011 (RT) Caravan / Town & Country
NOTE: This bulletin applies to vehicles equipped with brake sales code BRE and/or
BRG built after January, 01, 2009 and before May, 02, 2011.
SYMPTOM/CONDITION:
Vibration at the front of the vehicle when braking.
DIAGNOSIS:
1. Road test the vehicle for 5 minutes and intermittently apply the brakes.
2. Were there any vibrations experienced when braking?
a. Yes>>> Proceed to the repair procedure.
b. No>>> Proceed to Step #3.
3. Remove both front tire and wheel assemblies. Refer to the service information outlined
in DealerCONNECT>TechCONNECT>Service Information tab>22 - Tires and
Wheels>Removal
4. Using a Brake Lining Thickness Gauge or Brake Pad/Shoe Gauge, measure brake
pad thickness.
5. Perform the repair procedure if the brake pad usable material measured at its thinnest
point measures 4mm (0.1575 inches) or less.
NUMBER: 05-007-11
GROUP: Brakes
DATE: October 11, 2011
PARTS REQUIRED:
Qty. Part No. Description
AR (1) CNXBX361AA Kit, Front Brake Pad
AR (1) CNM2X252AB Kit, Front Brake Rotor (Contains 2 Rotors)
REPAIR PROCEDURE:
1. Remove the front brake pads. Refer to the service information outlined in
DealerCONNECT>TechCONNECT>Service Information tab>05 - Brakes> 05 -
Brakes, Base, Brake>Hydraulic/Mechanical>PADS, Brake, Front>Removal.
2. Remove any clips retaining the brake rotor to the wheel mounting studs.
3. Slide the brake rotor off the hub and bearing.
4. Clean the hub face to remove any dirt or corrosion where the rotor mounts.
5. Perform Step #2 through Step #4 on the opposite side of the vehicle.
6. Install brake rotors p/n CNM2X252AB over the studs on the hub and bearing on both
sides of the vehicle.
NOTE: Rotor replacement is recommended when switching to this type brake pad.
Standard brake service procedures apply thereafter.
7. Install new pads p/n CNXBX361AA. Refer to the service information outlined in
DealerCONNECT>TechCONNECT>Service Information tab>05 - Brakes> 05 -
Brakes, Base, Brake>Hydraulic/Mechanical>PADS, Brake, Front>Installation.
POLICY:
Reimbursable within the provisions of the warranty.
Vehicles included in this Service Bulletin applies to U.S. Market (sales code YAA), Canada
Market (sales code YAC) and Mexico Market (Sales Code YAD). See Warranty Bulletins;
U.S. D-11-52, Canada SAB-2011-29, Virgin Islands and Puerto Rico ID-11-06 for details
associated with the extended warranty.
TIME ALLOWANCE:
Labor Operation No: Description Amount
05-70-22-96 Inspect Front Brake Pads Only (B) 0.2 Hrs.
05-70-22-97 Inspect & Install New Front Pads,
Replace Both Front Rotors (B)
0.6 Hrs.
FAILURE CODE:
ZZ Service Action
05-007-11 -2-
__________________

 

So I'm getting that some of you have a pretty easy time getting the wiper arm off. (Maybe I should make it an annual maintenance thing?) But in my experience, with both a 2003 GC and a 2006 GC, this was anything but easy.

The battery post removal tool was the first thing I tried, and could tell the tool was starting to bend out of shape with no sign of the wiper arm even starting to budge. Then I picked up a tool specific to wiper arm removal, it looked heavier duty than the battery post removal tool, but it started bending at the turn handle. Had it been just the 2003 GC, I would have thought nothing of it, but when it happened on the replacment 2006 GC, I figured this was a more common problem. I used the 3-arm puller from Harbor Freight, and this still required signficant torque. When the puller finally won, the wiper arm came off with a big bang, loud enough that the wifey heard it from inside the house and came out to make sure I was o.k.

(Before I did all of the above, I used a rubber mallet to tap the sides of the wiper arm in an attempt to loosen a stuck grip, and also used Kroil after I removed the nut holding down the wiper arm.)

 

Replace Water Pump '99 Caravan with 3.0 Liter Mitsubishi engine


Here is what you need to remove to get the water pump off off of the engine -- no more.

-- Disconnect battery negative

-- Raise front of van on jack stands

-- Remove RF wheel and spash shields to expose lower front of engine from the wheel well.

-- Loosen radiator cap to remove pressure

-- Remove lower radiator hose from radiator to drain radiator coolant

-- Remove air conditioner pulley from the crankshaft, and remove air conditioner belt and pulley together.

-- Remove the serpentine belt

-- Use impact wrench to loosen the harmonic dampener bolt, and then remove the serpentine pulley bolt from the crankshaft, and remove those components from the crankshaft.

-- Disconnect any electrical harnesses that get in the way, including the one to the air conditioner compressor.

-- Support the bottom of the engine with a jack under the oil pan (pad with a piece of wood).

-- Remove large top bolt and cross bolt from the engine mount. and disconnect engine mount from fender bracket. Also Remove bracket from the fender.

-- Remove the idler pulley for the serpentine belt.

-- Remove two bolts that go through the power steering pump into the front engine mount bracket that is still bolted to the engine. Guide the bolts out through one of the holes in the power steering pump pulley.

-- Go to the rear of the engine, and loosen one mounting bolt for the power steering pump, and remove the other, so that the power steering pump remains there attached loosely, but can be rocked around from the front.

-- Remove harness and nuts that hold the A/C compressor to its bracket, and slide the compressor out enough to access bolts to remove the compressor bracked from the engine. You do NOT need to disconnect the air condition hoses. Just let the compressor hang hang there.

-- Despite what some instructions say, you do not need to loosen the alternator or its bracket.

-- Remove the remainder of the bolts holding the engine mount bracket to the front of the engine. One long bolt might have trouble getting past the top of the inner fender. If so, raise the engine slightly with its jack until it clears and the bolt can be removed.

-- Take the engine mount support bracket off the front of the engine. You’ll need to tilt it away from the engine on the right side (as you look at it) and guide it out from behind the power steering pump pulley, which should be loose enough to give sufficient room to guide it out..

-- Remove the covers for the timing belt.

-- Suggest you get the timing belt pulley marks aligned to their pulley positions. Then put a mark on each pulley and a mark on the timing belt at the corresponding space on the timing belt. This will help when you put the belt back on. Even if you decide to put a new timing belt on, later you can lay them both on the floor and count the teeth to put the same marks on the new belt in the same place, to match the marks on the pulleys you put there earlier, when you install the new belt.

-- Remove the timing belt tensioner spring

-- Remove the timing belt.

-- Remove the water pump.

The water pump is held onto the engine by the larger bolts, mostly around the lower half of the pump going straight into the front of the engine, and one larg bolt coming down vertically into the top of the pump through a strap plate that is bolted to the alternator bracket. All of the smaller bolts around the top do NOT have to be removed at all to remove the water pump from the engine. The smaller bolts are only there to hold the two halves of the water pump together, along with a screw coming in from the back of the pump. These can be removed later, once the water pump is off the car.


-- The water pump should pull straight out and off. It is pushed on a water pipe to the engine with a rubber seal, so you might have to work it a little to get it to pull out forward.

--While the water pump is off, you might consider putting on a new timing belt, and a new lower crankshaft seal, and maybe new front cam seals. Instructions to change these can be found elsewhere on the internet.

-- Reassemble in reverse order.

-- When torquing the large harmonic balancer bolt while reinstalling, buy two longish bolts to put into the crankshaft where the serpentine belt pulley bolts to the front damper. These can be used with a bar to keep the crankshaft from rotating while torquing the damper bolt.

-- Dealers say this is a 4.5 hour labor job. Maybe if you’ve done several of them, you might be able to do in that time. I’d plan for at least twice that long.

 

This for the 1996 thru 2000 minvans.

FRONT SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
Strut Assembly:
Strut Tower Attaching Nuts 28 N·m (250 in. lbs.)
Steering Knuckle Attaching bolts 88 N·m(65 ft. lbs.) Plus 1/4 Additional Turn
Strut Shaft Nut 100 N·m (75 ft. lbs.)
Steering Knuckle:
Ball Joint Stud Nut/Bolt 145 N·m (105 ft. lbs.)
Disc Brake Caliper Bolts 41 N·m (30 ft. lbs.)
Wheel Stop 95 N·m (70 ft. lbs.)
Hub And Bearing:
Mounting Bolts 65 N·m (45 ft. lbs.)
Hub Nut 244 N·m (180 ft. lbs.)
Wheel Mounting Lug Nuts 135 N·m (100 ft. lbs.)
Lower Control Arm:
Lower Control Arm Pivot Bolt 185 N·m(137 ft. lbs.)
Lower Control Arm Rear BushingRetainer Bolt 68 N·m (50 ft. lbs.)
Stabilizer Bar:
Bushing Retainer Cradle AttachingBolts 70 N·m (50 ft. lbs.)
Attaching Link Nuts 88 N·m (65 ft. lbs.)
Front Suspension Cradle:
Body Attaching Bolts 163 N·m (120 ft. lbs.)
Reinforcement Plate AttachingBolts M-12 108 N·m (80 ft. lbs.)
Reinforcement Plate AttachingBolts M-14 166 N·m (123 ft. lbs.)

 

I can't get this to work. I've replaced the radio with an after market one,would that affect this test?

 

.....