Engine System Testing & Engine Component Testing - Except Sebring Coupe & Stratus Coupe: Other Chrysler 300M I

POWERTRAIN CONTROL MODULE

Note. If replacing Powertrain Control Module (PCM), the correct vehicle mileage and Vehicle Identification Number (VIN) must be programmed into the PCM to prevent Diagnostic Trouble Codes (DTCs) from being set in the Controller Anti-Lock Brake (CAB) module, Sentry Key Immobilizer Module (SKIM) and Supplemental Restraint System (SRS) module. To program PCM and clear DTCs from CAB, SKIM and SRS modules, proceed to appropriate procedure.

Note. If replacing both PCM and SKIM at the same time, first program PCM, then program SKIM. Replace all ignition keys and program them to new SKIM.

Programming PCM

1. Connect scan tool to Data Link Connector (DLC). DLC is located below driver's side of instrument panel, near steering column.
2. Using scan tool, select THEFT ALARM, SKIM then MISC. Select PCM REPLACED. Obtain 4-digit Personal Identification Number (PIN) from vehicle owner or manufacturer. NOTE: If 3 attempts are made incorrectly to enter PIN, secured access mode will be locked out for one hour. To exit lock out mode, leave ignition switch in ON position for one hour. Ensure battery voltage is maintained with battery charger, if necessary.
3. Enter secured access mode by entering PIN code for vehicle. Select ENTER to update PCM VIN. SKIM will now send secret key data to PCM.
4. Select BACK to go to SELECT SYSTEM menu. Select ENGINE, MISC then SRI MEMORY CHECK. Scan tool will display IS ODOMETER READING BETWEEN XX AND XX?
5. Select YES or NO. If NO is selected, scan tool will display ENTER ODOMETER READING. Enter odometer reading from instrument panel and press ENTER.

Programming SKIM

1. Connect scan tool to Data Link Connector (DLC). DLC is located below driver's side of instrument panel, near steering column. Using scan tool, select THEFT ALARM, SKIM then MISC. Select PCM REPLACED. Obtain 4-digit Personal Identification Number (PIN) from vehicle owner or manufacturer. CAUTION: Enter correct country code in SKIM. If incorrect country code is entered, SKIM must be replaced. NOTE: If 3 attempts are made incorrectly to enter PIN, secured access mode will be locked out for one hour. To exit lock out mode, leave ignition switch in ON position for one hour. Ensure battery voltage is maintained with battery charger, if necessary.
2. Enter secured access mode by entering PIN code for vehicle. Select COUNTRY CODE. Enter correct country. Select YES to update VIN. SKIM will learn VIN from Powertrain Control Module (PCM). Press ENTER to transfer secret key data from PCM to SKIM. Program ignition keys to SKIM.

Programming Ignition Keys To SKIM

1. Connect scan tool to Data Link Connector (DLC). DLC is located below driver's side of instrument panel, near steering column. Using scan tool, select THEFT ALARM, SKIM then MISC. Select PROGRAM IGNITION KEYS. Obtain 4-digit Personal Identification Number (PIN) from vehicle owner or manufacturer. NOTE: If 3 attempts are made incorrectly to enter PIN, secured access mode will be locked out for one hour. To exit lock out mode, leave ignition switch in ON position for one hour. Ensure battery voltage is maintained with battery charger, if necessary. NOTE: A maximum of 8 keys can be learned to each SKIM. Once a key is learned to SKIM, key cannot be transferred to another vehicle.
2. Enter secured access mode by entering PIN code for vehicle. Obtain ignition keys to be programmed from customer. Select MISC, then ERASE ALL CURRENT IGN KEYS. Program all ignition keys by following instructions on scan tool.

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS to ensure system is functioning properly.

PCM LOCATION

Checking PCM Power & Ground Circuits (Concorde, Intrepid, LHS, Neon, PT Cruiser & 300M)

1. Turn ignition off. Disconnect PCM harness connectors. For PCM location, see «PCM LOCATION»(ref-97005-S39311391702001042600000) table. Connect a test light between ground and fused battery voltage circuit (Red/White wire) at PCM C2 harness connector terminal No. 46. (Scheme 29)or (Scheme 30). If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in fused battery voltage circuit.
2. Turn ignition on. Connect a test light between ground and fused ignition switch output circuit (Dark Blue/White wire) at PCM C1 harness connector terminal No. 20. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in fused ignition switch output circuit.
3. Turn ignition off. Using a test light connected to battery positive, individually probe the following ground circuits: Black/Tan wire at PCM C1 harness connector terminal No. 10. Black/Tan wire at PCM C2 harness connector terminal No. 50. Black/White wire at PCM C2 harness connector terminal No. 47. If test light illuminates at each ground circuit, test is complete. If test light does not illuminate at each ground circuit, repair open in appropriate ground circuit.

Scheme 29

Scheme 30

Checking PCM Power & Ground Circuits (Sebring Convertible, Sebring Sedan & Stratus Sedan)

1. Turn ignition off. Disconnect PCM harness connectors. For PCM location, see «PCM LOCATION»(ref-97005-S39311391702001042600000) table. Connect a test light between ground and fused battery voltage circuit (Red/Tan wire) at PCM C2 harness connector terminal No. 46. (Scheme 30) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in fused battery voltage circuit.
2. Turn ignition on. Connect a test light between ground and fused ignition switch output circuit (Dark Blue/White wire) at PCM C1 harness connector terminal No. 20. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in fused ignition switch output circuit.
3. Turn ignition off. Using a test light connected to battery positive, individually probe the following ground circuits: Black/Tan wire at PCM C1 harness connector terminal No. 10. Black/Tan wire at PCM C2 harness connector terminal No. 50. Black wire at PCM C2 harness connector terminal No. 47. If test light illuminates at each ground circuit, test is complete. If test light does not illuminate at each ground circuit, repair open in appropriate ground circuit.

AMBIENT/BATTERY TEMPERATURE SENSOR

See related test under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

BAROMETRIC PRESSURE SENSOR

See DTC P0106: BAROMETRIC PRESSURE OUT OF RANGE under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

CAMSHAFT POSITION SENSOR

For camshaft position sensor testing, see DTC P0340: NO CAM SIGNAL AT PCM under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

CHECKING ECT SENSOR

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

Note. Thermostat must be operating properly for this test to be valid. This test works best if engine was allowed to cool overnight.

Turn ignition on. Using scan tool, read engine coolant temperature. If engine was allowed to cool overnight, engine coolant temperature should be close to ambient temperature. If engine coolant temperature is more than 180°F (82°C), allow engine to cool until 150°F (66°C) is reached. Start engine. Using scan tool, monitor engine coolant temperature while engine is warming up. Engine coolant temperature should increase smoothly to at least 180°F (82°C). If temperature increases as specified, test is complete. If temperature does not increase as specified, replace ECT sensor.

CHECKING INLET AIR TEMPERATURE (IAT) SENSOR

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

Note. On Concorde, Intrepid, LHS and 300M equipped with a 3.2L or 3.5L engine, a combination IAT/MAP sensor is used.

Turn ignition on. Using scan tool, read inlet air temperature. Turn ignition off. Within 5 minutes, remove IAT sensor. On Neon, IAT sensor is located in left front corner of engine compartment, on air intake duct. For all other models (Scheme 31)- (Scheme 35). On all models, using a temperature probe, measure air temperature inside IAT sensor opening. If air temperature is within 10°F of temperature displayed on scan tool, test is complete. If air temperature is not within 10°F of temperature displayed on scan tool, check for high resistance in IAT sensor wiring. Repair wiring as necessary. If wiring is okay, replace IAT sensor.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

CHECKING MAP SENSOR

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

Turn ignition off. Connect a vacuum gauge to a manifold vacuum source. Start engine and let it idle. If engine will not idle, maintain a constant RPM above idle. Using scan tool, monitor MAP sensor vacuum. If scan tool reading is within one in. Hg of vacuum gauge reading, test is complete. If scan tool reading is not within one in. Hg of vacuum gauge reading, replace MAP sensor.

CHECKING TP SENSOR

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

Note. Before proceeding, ensure throttle plate and linkage are operating properly and are free from binding.

1. Turn ignition on. Using scan tool, read TP sensor voltage. If voltage is 1.5 volts or less, go to next step. If voltage is 1.5 volts or more, replace TP sensor.
2. While monitoring TP sensor voltage on scan tool, slowly open and close throttle. Voltage should be about .8 volt at idle, and increase smoothly to more than 3.5 volts at wide open throttle. If voltage is not as specified, replace TP sensor. If voltage is as specified, TP sensor is operating normally. Test is complete.

CRANKSHAFT POSITION SENSOR

For crankshaft position sensor testing, see DTC P0320: NO CRANK REFERENCE SIGNAL AT PCM under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

HEATED OXYGEN SENSOR (HO2S)

See related test under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

KNOCK SENSOR (EXCEPT NEON & PT CRUISER)

See DTC P0325: KNOCK SENSOR CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

LEAK DETECTION PUMP SWITCH

For leak detection pump switch testing, see DTC P1494: LEAK DETECTION PUMP SW OR MECHANICAL FAULT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

See related test under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

PARK/NEUTRAL POSITION SWITCH (A/T)

For park/neutral position switch testing, see DTC P1899: P/N SWITCH PERFORMANCE under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

POWER STEERING SWITCH

For power steering switch testing, see DTC P0551: POWER STEERING SWITCH FAILURE under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

VEHICLE SPEED SENSOR

For vehicle speed sensor testing, see DTC P0500: NO VEHICLE SPEED SENSOR SIGNAL under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

A/C CLUTCH RELAY

Note. For A/C clutch relay circuit testing, see DTC P0645: A/C CLUTCH RELAY CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

Checking A/C Clutch Relay Output (Concorde, Intrepid, LHS & 300M)

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition on. Using scan tool, actuate A/C clutch relay. A/C clutch relay is located in Power Distribution Center (PDC). PDC is located in engine compartment. (Scheme 36) If A/C clutch relay is not actuating, go to next step. If A/C clutch relay is actuating, A/C clutch relay output circuit is operating properly at this time. Test is complete.
2. Turn ignition off. Disconnect A/C compressor clutch harness connector. Measure resistance between ground and Black wire at A/C compressor clutch harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in ground circuit.
3. Turn ignition on. Using scan tool, actuate A/C clutch relay. Measure voltage between ground and A/C clutch relay output circuit (Dark Blue/Black wire) at A/C compressor clutch harness connector. If voltage is 11 volts or less, go to next step. If voltage is more than 11 volts, replace A/C compressor clutch.
4. Turn ignition off. Remove A/C clutch relay from PDC. Connect a test light between ground and fused battery voltage circuit (Red/Brown wire) at A/C clutch relay harness connector terminal "B" in PDC. (Scheme 36) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or short in fused battery voltage circuit.
5. Measure resistance of A/C clutch relay output circuit (Dark Blue/Black wire) between A/C compressor clutch harness connector and A/C clutch relay harness connector terminal "D" in PDC. If resistance is less than 5 ohms, replace A/C clutch relay. If resistance is 5 ohms or more, repair open in A/C clutch relay output circuit.

Scheme 36

Checking A/C Clutch Relay Output (Neon)

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition on. Using scan tool, actuate A/C clutch relay. A/C clutch relay is located in Power Distribution Center (PDC). PDC is located in engine compartment. (Scheme 37) If A/C clutch relay is not actuating, go to next step. If A/C clutch relay is actuating, A/C clutch relay output circuit is operating properly at this time. Test is complete.
2. Turn ignition off. Disconnect A/C compressor clutch harness connector. Measure resistance between ground and Black wire at A/C compressor clutch harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in ground circuit.
3. Turn ignition on. Using scan tool, actuate A/C clutch relay. Measure voltage between ground and A/C clutch relay output circuit (Dark Blue/Black wire) at A/C compressor clutch harness connector. If voltage is 11 volts or less, go to next step. If voltage is more than 11 volts, replace A/C compressor clutch.
4. Turn ignition off. Remove A/C clutch relay from PDC. Connect a test light between ground and fused battery voltage circuit (Red/Light Green wire) at A/C clutch relay harness connector terminal No. 30 in PDC. (Scheme 37) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or short in fused battery voltage circuit.
5. Measure resistance of A/C clutch relay output circuit (Dark Blue/Black wire) between A/C compressor clutch harness connector and A/C clutch relay harness connector terminal No. 31 in PDC. If resistance is less than 5 ohms, replace A/C clutch relay. If resistance is 5 ohms or more, repair open in A/C clutch relay output circuit.

Scheme 37

Checking A/C Clutch Relay Output (PT Cruiser)

Information is not available from manufacturer.

Checking A/C Clutch Relay Output (Sebring Convertible, Sebring Sedan & Stratus Sedan)

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition on. Using scan tool, actuate A/C clutch relay. A/C clutch relay is located in Power Distribution Center (PDC). PDC is located in engine compartment. (Scheme 38) If A/C clutch relay is not actuating, go to next step. If A/C clutch relay is actuating, A/C clutch relay output circuit is operating properly at this time. Test is complete.
2. Turn ignition off. Disconnect A/C compressor clutch harness connector. Measure resistance between ground and Black wire at A/C compressor clutch harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in ground circuit.
3. Turn ignition on. Using scan tool, actuate A/C clutch relay. Measure voltage between ground and A/C clutch relay output circuit (Dark Blue/Black wire) at A/C compressor clutch harness connector. If voltage is 11 volts or less, go to next step. If voltage is more than 11 volts, replace A/C compressor clutch.
4. Turn ignition off. Remove A/C clutch relay from PDC. Connect a test light between ground and fused battery voltage circuit (Red/Light Green wire) at A/C clutch relay harness connector terminal No. 64 in PDC. (Scheme 38) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or short in fused battery voltage circuit.
5. Measure resistance of A/C clutch relay output circuit (Dark Blue/Black wire) between A/C compressor clutch harness connector and A/C clutch relay harness connector terminal No. 63 in PDC. If resistance is less than 5 ohms, replace A/C clutch relay. If resistance is 5 ohms or more, repair open in A/C clutch relay output circuit.

Scheme 38

AUTO SHUTDOWN RELAY

For Auto Shutdown (ASD) relay circuit testing, see DTC P1388: AUTO SHUTDOWN RELAY CONTROL CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

EVAPORATIVE PURGE SOLENOID

For evaporative purge solenoid testing, see DTC P0443: EVAP PURGE SOLENOID CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

FUEL PUMP RELAY

For fuel pump relay testing, see DTC P1282: FUEL PUMP RELAY CONTROL CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

IDLE AIR CONTROL MOTOR

For idle air control motor testing, see IDLE CONTROL SYSTEMS .

RADIATOR FAN RELAY

For radiator fan relay output circuit testing, see MISCELLANEOUS CONTROLS . For radiator fan relay control circuit testing, see DTC P1489: HIGH SPEED FAN CONTROL RELAY CIRCUIT or DTC P1490: LOW SPEED FAN CONTROL RELAY CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

FUEL SYSTEM PRESSURE RELEASE

1. Turn ignition off. Remove fuel pump relay from Power Distribution Center (PDC). PDC is located in engine compartment. Start engine and let it idle until engine stalls. Attempt restarting engine until engine will no longer run. Turn ignition off. Remove fuel tank filler cap from fuel tank to release any pressure from fuel tank.
2. Fuel system components may now be serviced. Use care when servicing fuel system components, as some fuel pressure may still exist in the fuel system. Install fuel tank filler cap and fuel pump relay once fuel system components are serviced.
3. Diagnostic Trouble Code (DTC) may have been stored in PCM due to the removal of fuel pump relay. Clear DTCs from PCM. See CLEARING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article.

Concorde, Intrepid, LHS & 300M

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition on. Using scan tool, actuate ASD fuel system test. Listen for fuel pump operation at fuel tank. It may be necessary to use a stethoscope. If fuel pump operation can be heard, fuel pump is operating. Stop fuel system activation and go to next step. If fuel pump operation cannot be heard, stop fuel system activation and go to step 7.
2. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-97005-S24294239202001042400000). Connect a fuel pressure gauge to test port on fuel rail. Using scan tool, actuate ASD fuel system test. Observe fuel pressure gauge. Fuel pressure should be 53-63 psi (365-434 kPa). Stop ASD fuel system test. If fuel pressure is less than specification, go to next step. If fuel pressure is within specification, go to step 5. If fuel pressure is more than specification, replace fuel filter/pressure regulator.
3. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel filter/pressure regulator at fuel tank. Connect Fuel Line Adapter (6539) between disconnected fuel line and fuel pump module. Connect fuel pressure gauge to fuel line adapter hose. Turn ignition on. Using scan tool, actuate ASD fuel system test and note fuel pressure. Fuel pressure should be 53-63 psi (365-434 kPa). Stop ASD fuel system test. If fuel pressure is as specified, repair or replace fuel supply line as necessary. If fuel pressure is not as specified, go to next step.
4. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. If fuel inlet strainer is plugged, replace fuel pump inlet strainer. If fuel inlet strainer is not plugged, replace fuel pump module.
5. Turn ignition off. Release fuel pressure. Disconnect fuel supply line from fuel rail. Install Fuel Line Adapter (6539 for 5/16" fuel lines or 6631 for 3/8" fuel lines) between disconnected fuel line and fuel rail. Insert other end of hose into a graduated container suitable for gasoline. CAUTION: DO NOT operate fuel pump longer than 7 seconds.
6. Using scan tool, actuate ASD fuel system test for 7 seconds. If fuel volume is.5 pt (.25L) or more, no problem is indicated at this time. Test is complete. If fuel volume is less than.5 pt (.25L), check for a kinked fuel line between fuel pump module and fuel rail. Repair fuel lines as necessary and retest. If fuel line is okay, replace fuel pump module.
7. Turn ignition off. Disconnect fuel pump module harness connector. Inspect connector for damage or corrosion. Clean or repair connector as necessary. If connector is okay, turn ignition on. Using scan tool, actuate ASD fuel system test. Connect a test light between ground and fuel pump relay output circuit (Dark Green/White wire) at fuel pump module harness connector. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, go to step 10.
8. Turn ignition off. Connect a test light between battery positive terminal and ground circuit (Black wire) at fuel pump module harness connector. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in ground circuit. See WIRING DIAGRAMS article.
9. At this time, fuel pump module is assumed to be defective. Replace fuel pump module.
10. Turn ignition off. Remove fuel pump relay from PDC. Connect a test light between ground and fused battery voltage circuit (Red wire) at terminal "B" at fuel pump relay harness connector in PDC. (Scheme 36) If test light illuminates, go to next step. If test light does not illuminate, repair open in fused battery voltage circuit.
11. Measure resistance of fuel pump relay output circuit (Dark Green/White wire) between fuel pump module harness connector and terminal "D" at fuel pump relay harness connector in PDC. If resistance is less than 5 ohms, replace fuel pump relay. If resistance is 5 ohms or more, repair open in Dark Green/White wire between fuel pump module and PDC.

Neon

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition on. Using scan tool, actuate ASD fuel system test. Listen for fuel pump operation at fuel tank. It may be necessary to use a stethoscope. If fuel pump operation can be heard, fuel pump is operating. Stop fuel system activation and go to next step. If fuel pump operation cannot be heard, stop fuel system activation and go to step 7.
2. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-97005-S24294239202001042400000). Connect a fuel pressure gauge to test port on fuel rail. Using scan tool, actuate ASD fuel system test. Observe fuel pressure gauge. Fuel pressure should be 53-63 psi (365-434 kPa). Stop ASD fuel system test. If fuel pressure is less than specification, go to next step. If fuel pressure is within specification, go to step 5. If fuel pressure is more than specification, replace fuel filter/pressure regulator.
3. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel filter/pressure regulator at fuel tank. Connect Fuel Line Adapter (6539) between disconnected fuel line and fuel pump module. Connect fuel pressure gauge to fuel line adapter hose. Turn ignition on. Using scan tool, actuate ASD fuel system test and note fuel pressure. Fuel pressure should be 53-63 psi (365-434 kPa). Stop ASD fuel system test. If fuel pressure is as specified, repair or replace fuel supply line as necessary. If fuel pressure is not as specified, go to next step.
4. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. If fuel inlet strainer is plugged, replace fuel pump inlet strainer. If fuel inlet strainer in not plugged, replace fuel pump module.
5. Turn ignition off. Release fuel pressure. Disconnect fuel supply line from fuel rail. Install Fuel Line Adapter (6539 for 5/16" fuel lines or 6631 for 3/8" fuel lines) between disconnected fuel line and fuel rail. Insert other end of hose into a graduated container suitable for gasoline. CAUTION: DO NOT operate fuel pump longer than 7 seconds.
6. Using scan tool, actuate ASD fuel system test for 7 seconds. If fuel volume is.5 pt (.25L) or more, no problem is indicated at this time. Test is complete. If fuel volume is less than.5 pt (.25L), check for a kinked fuel line between fuel pump module and fuel rail. Repair fuel lines as necessary and retest. If fuel line is okay, replace fuel pump module.
7. Turn ignition off. Disconnect fuel pump module harness connector. Inspect connector for damage or corrosion. Clean or repair connector as necessary. If connector is okay, turn ignition on. Using scan tool, actuate ASD fuel system test. Connect a test light between ground and fuel pump relay output circuit (Dark Green/White wire) at fuel pump module harness connector. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, go to step 10.
8. Turn ignition off. Connect a test light between battery positive terminal and ground circuit (Black wire) at fuel pump module harness connector. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in ground circuit. See WIRING DIAGRAMS article.
9. At this time, fuel pump module is assumed to be defective. Replace fuel pump module.
10. Turn ignition off. Remove fuel pump relay from PDC. Connect a test light between ground and fused battery voltage circuit (Red/White wire) at terminal No. 60 at fuel pump relay harness connector in PDC. (Scheme 37) If test light illuminates, go to next step. If test light does not illuminate, repair open in fused battery voltage circuit.
11. Measure resistance of fuel pump relay output circuit (Dark Green/White wire) between fuel pump module harness connector and terminal No. 61 at fuel pump relay harness connector in PDC. If resistance is less than 5 ohms, replace fuel pump relay. If resistance is 5 ohms or more, repair open in Dark Green/White wire between fuel pump module and PDC.

PT Cruiser

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-5 under VERIFICATION TESTS to ensure system is functioning properly.

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect fuel supply line from fuel rail. Connect 5/16" Fuel Line Adapter (6539) or 3/8" Fuel Line Adapter (6631) to disconnected fuel supply line. Insert other end of adapter into a graduated container. Turn ignition on. Using scan tool, actuate ASD fuel system test for 7 seconds. Fuel pump should deliver at least .5 pt (.25L) in 7 seconds. If fuel pump capacity is not as specified, check for kinked or damaged fuel supply line between fuel tank and fuel rail. If fuel line is okay, replace fuel pump module.

Sebring Convertible, Sebring Sedan & Stratus Sedan

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition on. Using scan tool, actuate ASD fuel system test. Listen for fuel pump operation at fuel tank. It may be necessary to use a stethoscope. If fuel pump operation can be heard, fuel pump is operating. Stop fuel system activation and go to next step. If fuel pump operation cannot be heard, stop fuel system activation and go to step 7.
2. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-97005-S24294239202001042400000). Connect a fuel pressure gauge to test port on fuel rail. Using scan tool, actuate ASD fuel system test. Observe fuel pressure gauge. Fuel pressure should be 53-63 psi (365-434 kPa). Stop ASD fuel system test. If fuel pressure is less than specification, go to next step. If fuel pressure is within specification, go to step 5. If fuel pressure is more than specification, replace fuel filter/pressure regulator.
3. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel filter/pressure regulator at fuel tank. Connect Fuel Line Adapter (6539) between disconnected fuel line and fuel pump module. Connect fuel pressure gauge to fuel line adapter hose. Turn ignition on. Using scan tool, actuate ASD fuel system test and note fuel pressure. Fuel pressure should be 53-63 psi (365-434 kPa). Stop ASD fuel system test. If fuel pressure is as specified, repair or replace fuel supply line as necessary. If fuel pressure is not as specified, go to next step.
4. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. If fuel inlet strainer is plugged, replace fuel pump inlet strainer. If fuel inlet strainer is not plugged, replace fuel pump module.
5. Turn ignition off. Release fuel pressure. Disconnect fuel supply line from fuel rail. Install 5/16" Fuel Line Adapter (6539) or 3/8" Fuel Line Adapter (6631) between disconnected fuel line and fuel rail. Insert other end of hose into a graduated container suitable for gasoline. CAUTION: DO NOT operate fuel pump longer than 7 seconds.
6. Using scan tool, actuate ASD fuel system test for 7 seconds. If fuel volume is.5 pt (.25L) or more, no problem is indicated at this time. Test is complete. If fuel volume is less than.5 pt (.25L), check for a kinked fuel line between fuel pump module and fuel rail. Repair fuel lines as necessary and retest. If fuel line is okay, replace fuel pump module.
7. Turn ignition off. Disconnect fuel pump module harness connector. Inspect connector for damage or corrosion. Clean or repair connector as necessary. If connector is okay, turn ignition on. Using scan tool, actuate ASD fuel system test. Connect a test light between ground and fuel pump relay output circuit (Dark Green/White wire) at fuel pump module harness connector. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, go to step 10.
8. Turn ignition off. Connect a test light between battery positive terminal and ground circuit (Black wire) at fuel pump module harness connector. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in ground circuit. See WIRING DIAGRAMS article.
9. At this time, fuel pump module is assumed to be defective. Replace fuel pump module.
10. Turn ignition off. Remove fuel pump relay from PDC. Connect a test light between ground and fused battery voltage circuit (Red wire) at terminal No. 16 at fuel pump relay harness connector in PDC. (Scheme 38) If test light illuminates, go to next step. If test light does not illuminate, repair open in fused battery voltage circuit.
11. Measure resistance of fuel pump relay output circuit (Dark Green/White wire) between fuel pump module harness connector and terminal No. 15 at fuel pump relay harness connector in PDC. If resistance is less than 5 ohms, replace fuel pump relay. If resistance is 5 ohms or more, repair open in Dark Green/White wire between fuel pump module and PDC.

CHECKING IDLE AIR CONTROL (IAC) MOTOR

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

Concorde, Intrepid, LHS, 300M, Sebring Convertible, Sebring Sedan & Stratus Sedan

1. Turn ignition on. Using scan tool, set engine speed to 1400 RPM. If engine speed does not reach 1400 RPM, go to next step. If engine speed reaches 1400 RPM, IAC motor is operating properly. Test is complete.
2. Turn ignition off. Disconnect IAC motor and PCM harness connectors. IAC motor is located on side of throttle body. For PCM location, see «PCM LOCATION»(ref-97005-S39311391702001042600000) table under COMPUTERIZED ENGINE CONTROLS. Measure resistance of the following: Gray/Red wire between IAC motor harness connector and terminal No. 57 at PCM C2 harness connector. Yellow/Black wire between IAC motor harness connector and terminal No. 49 at PCM C2 harness connector. Brown/White wire between IAC motor harness connector and terminal No. 48 at PCM C2 harness connector. Violet/Black wire between IAC motor harness connector and terminal No. 58 at PCM C2 harness connector. (Scheme 29)or (Scheme 30). If resistance is 5 ohms or more on any circuit, repair open in appropriate circuit. If resistance is less than 5 ohms on all circuits, replace IAC motor.

For IAC motor and circuit testing, see DTC P0508: IAC MOTOR SENSE CIRCUIT LOW or DTC P0509: IAC MOTOR SENSE CIRCUIT HIGH under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - NEON article.

1. Start engine and let it idle. Using scan tool, set engine speed to 1400 RPM. Wait 10 seconds. Using scan tool, set engine speed to 900 RPM. Wait 10 seconds. If engine RPM did not change from 1400 to 900 RPM, go to next step. If engine RPM changed from 1400 to 900 RPM, test is complete.
2. With engine idling, check for vacuum leaks. If any vacuum leaks are found, repair as necessary. If no vacuum leaks are found, go to next step.
3. Turn ignition off. Disconnect IAC motor harness connector. IAC motor is located on side of throttle body. Start engine and let it idle. Connect a test light between ground and IAC driver No. 1 circuit (Gray/Red wire) at IAC motor harness connector. Wait 10 seconds. Repeat test for remaining 3 IAC driver circuits. If test light turns on and off while probing each IAC driver circuit, go to next step.If test light does not turn on and off while probing each IAC driver circuit, go to step 6.
4. With engine idling, connect a test light between battery positive terminal and IAC driver No. 1 circuit (Gray/Red wire) at IAC motor harness connector. Wait 10 seconds. Repeat test for remaining 3 IAC driver circuits. If test light turns on and off while probing each IAC driver circuit, go to next step.If test light does not turn on and off while probing each IAC driver circuit, replace PCM.
5. Turn ignition off. Inspect IAC motor harness connector for damaged, pushed out or miswired terminals. Clean or repair connector as necessary. If connector is okay, replace IAC motor.
6. Turn ignition off. Disconnect PCM harness connectors. PCM is located in left rear of engine compartment, behind brake master cylinder. Measure resistance of IAC motor driver circuit(s) between IAC motor harness connector and PCM C2 harness connector that indicated no test light illumination. (Scheme 30) If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in IAC motor driver circuit(s).

IGNITION COIL

For ignition coil control circuit testing, see related test under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article. For ignition coil resistance checks, see appropriate IGNITION COIL RESISTANCE table.

4-CYLINDER IGNITION COIL RESISTANCE - Ohms @ 70°F (21°C)

V6 IGNITION COIL RESISTANCE - Ohms @ 70°F (21°C)

EGR SYSTEM (EXCEPT NEON)

Note. For EGR system testing, see DTC P0401: EGR SYSTEM FAILURE under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

EGR Solenoid

See DTC P0403: EGR SOLENOID CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

EGR Position Sensor (Except PT Cruiser)

See DTC P0404: EGR POSITION SENSOR RATIONALITY, DTC P0405: EGR POSITION SENSOR VOLTAGE TOO LOW or DTC P0406: EGR POSITION SENSOR VOLTAGE TOO HIGH under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

FUEL EVAPORATIVE SYSTEM

Note. For EVAP system testing, see related test under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

EVAP Purge Solenoid

See DTC P0443: EVAP PURGE SOLENOID CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.

Positive Crankcase Ventilation (PCV) Valve

1. With engine running at curb idle, remove PCV valve from grommet. If valve is functioning properly, a hissing sound will be heard as air passes through valve.
2. With engine running, place finger over valve inlet. Strong vacuum should be felt at valve inlet. Stop engine. Remove and shake PCV valve to ensure a metallic clicking noise can be heard, indicating valve is free. Reinstall PCV valve.
3. Remove crankcase ventilation filter or oil filler cap from valve cover. Hold a piece of stiff paper over opening. After allowing about one minute for crankcase pressure stabilization, paper should be drawn against opening.
4. If paper is held against opening, performance is okay. If paper is not held against opening, replace PCV valve and retest. If performance does not improve, inspect system for restrictions and clean as necessary.

MISCELLANEOUS CONTROLS

Note. Although some of the controlled devices listed here are not technically engine performance components, they can affect driveability if they malfunction.

AUTOMATIC TRANSMISSION

For automatic transmission diagnostic information, see appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS.

RADIATOR FANS

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly.

Checking Radiator Fan Relay Output (Concorde, Intrepid, LHS & 300M)

Note. The following test can be used for either low or high speed radiator fan relay output circuits.

1. Turn ignition on. Using scan tool, actuate appropriate radiator fan relay. If radiator fan does not operate, go to next step. If radiator fan operates, system is operating properly at this time. Test is complete.
2. Turn ignition off. Disconnect radiator fan motor harness connector. Measure resistance between ground and ground circuit (Black wire) at radiator fan motor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in ground circuit.
3. Turn ignition on. Using scan tool, actuate inoperative radiator fan relay. Measure voltage between ground and low speed radiator fan relay output circuit (Dark Green wire) or high speed radiator fan relay output circuit (Yellow wire) at radiator fan motor harness connector. If voltage is 11 volts or less, go to next step. If voltage is more than 11 volts, replace radiator fan motor.
4. Turn ignition off. Remove appropriate radiator fan relay from Power Distribution Center (PDC). PDC is located in engine compartment. (Scheme 36) Connect a test light between ground and fused battery voltage circuit at low speed radiator fan relay harness connector terminal "B" (Gray wire) or high speed radiator fan relay harness connector terminal "B" (Red/Brown wire). (Scheme 36) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or short in fused battery voltage circuit.
5. Measure resistance of appropriate radiator fan relay output circuit (Dark Green wire for low speed; Yellow wire for high speed) between terminal "D" at appropriate radiator fan relay harness connector and radiator fan motor harness connector. If resistance is less than 5 ohms, replace appropriate radiator fan relay. If resistance is 5 ohms or more, repair open in appropriate radiator fan relay output circuit.

Checking Radiator Fan Relay Output (Neon)

1. Turn ignition on. Using scan tool, actuate radiator fan relay. If radiator fan does not operate, go to next step. If radiator fan operates, system is operating properly at this time. Test is complete.
2. Turn ignition off. Disconnect radiator fan motor harness connector. Measure resistance between ground and ground circuit (Black wire) at radiator fan motor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in ground circuit.
3. Turn ignition on. Using scan tool, actuate radiator fan relay. Measure voltage between ground and radiator fan relay output circuit (Light Green wire) at radiator fan motor harness connector. If voltage is 11 volts or less, go to next step. If voltage is more than 11 volts, replace radiator fan motor.
4. Turn ignition off. Remove radiator fan relay from Power Distribution Center (PDC). PDC is located in engine compartment. (Scheme 37) Connect a test light between ground and fused battery voltage circuit (Gray wire) at radiator fan relay harness connector terminal No. 73. (Scheme 37) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or short in fused battery voltage circuit.
5. Measure resistance of radiator fan relay output circuit (Light Green wire) between terminal No. 71 at radiator fan relay harness connector and radiator fan motor harness connector. If resistance is less than 5 ohms, replace radiator fan relay. If resistance is 5 ohms or more, repair open in Light Green wire.

Check Radiator Fan Relay Output (Sebring Convertible, Sebring Sedan & Stratus Sedan)

Note. The following test can be used for either low or high speed radiator fan relay output circuits.

1. Turn ignition on. Using scan tool, actuate appropriate radiator fan relay. If radiator fan does not operate, go to next step. If radiator fan operates, system is operating properly at this time. Test is complete.
2. Turn ignition off. Disconnect radiator fan motor harness connector. Measure resistance between ground and ground circuit (Black wire) at radiator fan motor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in ground circuit.
3. Turn ignition on. Using scan tool, actuate inoperative radiator fan relay. Measure voltage between ground and low speed radiator fan relay output circuit (Dark Green wire) or high speed radiator fan relay output circuit (Yellow wire) at radiator fan motor harness connector. If voltage is 11 volts or less, go to next step. If voltage is more than 11 volts, replace radiator fan motor.
4. Turn ignition off. Remove appropriate radiator fan relay from Power Distribution Center (PDC). PDC is located in engine compartment. (Scheme 38) Connect a test light between ground and fused battery voltage circuit (Red/Light Green wire) at low speed radiator fan relay harness connector terminal No. 74 or high speed radiator fan relay harness connector terminal No. 79. (Scheme 38) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or short in fused battery voltage circuit.
5. Measure resistance of appropriate radiator fan relay output circuit (Dark Green wire for low speed; Yellow wire for high speed) between terminal "D" at appropriate radiator fan relay harness connector and radiator fan motor harness connector. If resistance is less than 5 ohms, replace appropriate radiator fan relay. If resistance is 5 ohms or more, repair open in appropriate radiator fan relay output circuit.