Engine Controls - Basic Diagnostic Procedures: Other Chrysler Voyager IV

POWERTRAIN CONTROL MODULE

Note. If Powertrain Control Module (PCM) is replaced, the correct vehicle mileage and Vehicle Identification Number (VIN) must be programmed into PCM to prevent Diagnostic Trouble Codes (DTC) from being stored in Controller Anti-Lock Brake (CAB), Smart Key Immobilizer Module (SKIM), if equipped and Occupant Restraint Controller (ORC). If replacing PCM on models equipped with a SKIM, the secret key data must also be updated to enable engine starting.

Programming Powertrain Control Module

Connect scan tool to Data Link Connector (DLC). The DLC is located below driver's side of instrument panel. (Scheme 86) Using scan tool, enter correct VIN and mileage into PCM. Using scan tool manufacturer's instructions, clear DTCs from CAB, SKIM and ORC modules.

Updating Secret Key Data

1. Connect scan tool to Data Link Connector (DLC). The DLC is located below driver's side of instrument panel. (Scheme 86) Ensure transmission is in Park. Turn ignition on. Using scan tool, select THEFT ALARM, SKIM and then MISCELLANEOUS. Select PCM REPLACED.
2. Place the SKIM in SECURED ACCESS MODE by entering the appropriate Personal Identification Number (PIN) for this vehicle. PIN may be obtained from the owner, vehicle's invoice, or from the manufacturer. Press ENTER to transfer secret key data from Sentry Key Immobilizer Module (SKIM) to the PCM. This will enable the vehicle to start.
3. If 3 attempts are made to enter the SECURED ACCESS MODE by using an incorrect PIN, the SECURED ACCESS MODE will be locked out for one hour. To exit lock out mode, leave ignition on with all accessories turned off. After one hour, enter correct PIN. It may be necessary to monitor battery voltage and connect a battery charger.

Scheme 86

Cylinder Compression Pressure

Check engine mechanical condition with a compression gauge, vacuum gauge, or scan tool. See scan tool manual for specific instructions. Ensure battery is fully charged, engine is at normal operating temperature and throttle valve is fully open when checking compression. Remove Auto Shutdown relay from Integrated Power Module (IPM). IPM is located on left side of engine compartment, next to battery. Clean spark plug recesses with compressed air. Remove all spark plugs. Install compression gauge into No. 1 spark plug hole. Hold throttle in Wide Open Throttle (WOT) position. Crank engine until maximum pressure is reached. Note pressure reading and repeat for remaining cylinders. See COMPRESSION SPECIFICATIONS table for correct engine compression pressures.

COMPRESSION SPECIFICATIONS

Scheme 87

Scheme 88

Cylinder Combustion Pressure Leakage

The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect exhaust and intake valve leaks (improper seating), leaks between adjacent cylinders or into water jacket, or any causes for combustion/compression pressure loss.

1. Check the coolant level and fill as required. Do not install the radiator cap. Start and operate the engine until it attains normal operating temperature, then turn the engine off. Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner.
2. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 70 psi (483 kPa) minimum and 200 psi (1379 kPa) maximum. Eighty psi (552 kPa) is recommended.
3. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set piston of cylinder to be tested at TDC of compression stroke. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant. All gauge pressure indications should be equal, with no more than 25 percent leakage. For example: at 80 psi (552 kPa) input pressure minimum of 60 psi (414 kPa) should be maintained in the cylinder. If pressure is not as specified, diagnose pressure loss. See «CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS»(ref-99020-S40914352342002062400000) table.

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS

CHECKING ENGINE VACUUM

Note. Normal vacuum readings vary according to altitude.

Connect vacuum gauge to engine vacuum source. Start engine and allow engine to idle. Note engine vacuum reading. Engine vacuum should be steady and 13-22 in. Hg with engine at idle. While monitoring engine vacuum reading, quickly open and close the throttle several times and then allow engine to idle. If engine vacuum is within specification, test is complete. If engine vacuum is not within specification, check for vacuum leaks and repair as necessary. If no vacuum leaks are found, check for engine mechanical problem.

FUEL SYSTEM PRESSURE RELEASE

1. Remove fuel filler cap. Remove fuel pump relay from Integrated Power Module (IPM). IPM is located on left side of engine compartment, next to battery. (Scheme 87)and (Scheme 88). NOTE: The Intelligent Power Module (IPM) may also be referred to as Integrated Power Module (IPM) or Power Distribution Center (PDC).
2. Start and run engine until it stalls. Attempt to start engine. Continue restarting engine until it will no longer run. Turn ignition off.
3. Reinstall fuel pump relay in IPM. One or more Diagnostic Trouble Codes (DTC) may set when fuel pump relay is removed. Erase any DTCs that may have set after fuel pressure release procedure.

CHECKING FUEL DELIVERY

1. Locate Intelligent Power Module (IPM) on left side of engine compartment, next to battery. (Scheme 87) Inspect fuse No. 17 (20-amp) in IPM. (Scheme 88) If fuse is okay, go to next step. If fuse is blown, check for short to ground in fuel pump relay output circuit. Repair as necessary and replace fuse. Go to next step.
2. Turn ignition on. Using scan tool, actuate Auto Shutdown (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 8.
3. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-99020-S15801066592001061300000). 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 6. If fuel pressure is more than specification, replace fuel pressure regulator. See «FUEL PRESSURE REGULATOR»(ref-98966-S18316010932001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article.
4. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel pump module 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.
5. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. See «FUEL PUMP MODULE»(ref-98966-S11150099922001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If fuel inlet strainer is plugged, replace fuel pump inlet strainer. If fuel inlet strainer is not plugged, replace fuel pump module.
6. 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.
7. 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. See «FUEL PUMP MODULE»(ref-98966-S11150099922001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article.
8. 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. Using a test light connected to ground, probe Dark Blue/Orange 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 11.
9. Turn ignition off. Using a test light connected to positive battery voltage, probe Black/Orange and Black/Dark Blue wires 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 Black/Orange wire or Black/Dark Blue wire. See «WIRING DIAGRAMS»(ref-132832) article.
10. At this time, fuel pump module is assumed to be defective. Replace fuel pump module.
11. Turn ignition off. Remove fuel pump relay from IPM. (Scheme 88) Using a test light connected to ground, probe terminal No. 87 at fuel pump relay socket in IPM. If test light illuminates, go to next step. If test light does not illuminate, check for an open fuel pump fuse (fuse No. 17) in IPM. If fuse is open, check for cause of fuse to blow. Repair as necessary and replace fuse. If fuse is okay, replace IMP.
12. Disconnect IPM C8 Orange connector. (Scheme 89) Measure resistance of Dark Blue/Orange wire between fuel pump module harness connector and terminal No. 2 at IPM C8 harness connector. (Scheme 90) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Blue/Orange wire.
13. Measure resistance of Dark Blue/Orange wire between fuel pump module harness connector and terminal No. 30 at fuel pump relay socket in IPM. If resistance is less than 5 ohms, replace fuel pump relay. If resistance is 5 ohms or more, replace IPM.

Scheme 89

Scheme 90

Fuel Pump Relay

Individual fuel pump relay testing is not available from manufacturer. For fuel pump relay circuit testing, see DTC P1282: FUEL PUMP RELAY CONTROL CIRCUIT under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER article.

IGNITION SYSTEMS

Note. Individual component testing for ignition coil is not available from manufacturer.

CAMSHAFT POSITION SENSOR

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

CRANKSHAFT POSITION SENSOR

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

IDLE SPEED

Manufacturer does not list procedure for checking idle speed. Idle speed is controlled by Powertrain Control Module (PCM). No adjustment is required. PCM controls Idle Air Control (IAC) motor for proper idle speed. See SYSTEM & COMPONENT TESTING - CARAVAN, TOWN & COUNTRY, & VOYAGER article for diagnosis of IAC motor.

IGNITION TIMING

Ignition timing is controlled by PCM and is not adjustable.

NO-START TESTS

Note. Diagnostic tests are written specifically for Chrysler's Diagnostic Readout Box (DRB-III(R)) scan tool. A generic scan tool may not be capable of performing all necessary test functions.

ENGINE CRANKS BUT DOES NOT START

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-1 under VERIFICATION TESTS to ensure system is functioning properly.

1. The following checks must be performed before continuing with this test. Ensure battery is fully charged and in good condition. If battery is low, charge battery then attempt to start engine by cranking starter for 15 seconds, 3 consecutive times. This will allow any DTCs to set that may have been erased due to a dead battery. Ensure Powertrain Control Module (PCM) power and ground circuits are okay. See COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - CARAVAN, TOWN & COUNTRY, & VOYAGER article. Ensure PCM communicates with scan tool and no Diagnostic Trouble Codes (DTC) are present. See RETRIEVING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER article. Ensure PCI bus is functional. Using scan tool, attempt to communicate with instrument cluster and Sentry Key Immobilizer Module (SKIM). If scan tool does not communicate with instrument cluster or SKIM, diagnose communication failure. See COMMUNICATIONS in appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. Using scan tool select CLEAR PCM (BATT DISCONNECT). Crank engine over several times. Using scan tool, check for DTCs. If any DTCs are present, perform appropriate diagnostic test. See SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If no DTCs exist, go to next step.
2. Turn ignition off. Check Intelligent Power Module (IPM) for blown fuses. IPM is located on left side of engine compartment, next to battery. (Scheme 87)and (Scheme 88). Replace blown fuses and check related circuits for short to ground. If fuses are okay, go to next step.
3. Using scan tool, actuate Auto Shutdown (ASD) fuel system test. Using a mechanic's stethoscope, listen for fuel pump operation at fuel tank. If fuel pump operation cannot be heard, stop ASD fuel system actuation and go to step 10. If fuel pump operation can be heard, stop ASD fuel system actuation and go to next step.
4. Turn engine off. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-99020-S15801066592001061300000). Remove test port cap. Install a fuel pressure gauge at test port. Turn ignition on, with engine off. Using scan tool, actuate ASD fuel system test. Allow fuel pressure gauge to stabilize. Stop ASD fuel system activation. Fuel pressure should be 53-63 psi (365-434 kPa). If fuel pressure is less than specified, go to next step. If fuel pressure is more than specified, replace fuel pressure regulator. See «FUEL PRESSURE REGULATOR»(ref-98966-S18316010932001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If fuel pressure is as specified, go to step 7.
5. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel pump module 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). If fuel pressure is as specified, stop ASD fuel system activation. Release fuel pressure, and repair or replace fuel supply line. If fuel pressure is not as specified, stop ASD fuel system activation and go to next step.
6. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. See «FUEL PUMP MODULE»(ref-98966-S11150099922001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If fuel inlet strainer is plugged, replace fuel pump inlet strainer. If fuel inlet strainer is not plugged, replace fuel pump.
7. Turn ignition off. Release fuel pressure. Disconnect fuel supply line from fuel rail. Install Fuel Line Pressure Test Adapter Hose (6539 for 5/16" fuel lines or 6631 for 3/8" fuel lines) between disconnected fuel line and fuel rail. Remove fuel fill cap. Insert other end of hose into a graduated container suitable for gasoline.
8. 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. See «FUEL PUMP MODULE»(ref-98966-S11150099922001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article.
9. Check the following additional items as possible causes for no-start condition: Check spark plug condition. Fuel must be free of contamination. Engine exhaust system must be free of restrictions. Engine compression must be within specification. Engine valve timing must be within specification. Engine vacuum must be at least 13 in. Hg with shift selector in Neutral. Repair any problems as necessary. If no problems exist, test is complete.
10. Turn ignition off. Disconnect fuel pump module connector. Turn ignition on. Using scan tool, actuate ASD fuel system test. Using a test light connected to ground, probe Dark Blue/Orange 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 13.
11. Turn ignition off. Using a test light connected to positive battery voltage, probe Black/Orange and Black/Dark Blue wires 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 Black/Orange wire or Black/Dark Blue wire. See «WIRING DIAGRAMS»(ref-132832) article.
12. At this time, fuel pump module is assumed to be defective. Replace fuel pump module.
13. Turn ignition off. Remove fuel pump relay from IPM. (Scheme 87)and (Scheme 88). Using a test light connected to ground, probe terminal No. 87 at fuel pump relay socket in IPM. If test light illuminates, go to next step. If test light does not illuminate, replace IMP.
14. Disconnect IPM C8 Orange connector. (Scheme 89) Measure resistance of Dark Blue/Orange wire between fuel pump module harness connector and terminal No. 2 at IPM C8 harness connector. (Scheme 90) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Blue/Orange wire.
15. Measure resistance of Dark Blue/Orange wire between fuel pump module harness connector and terminal No. 30 at fuel pump relay socket in IPM. If resistance is less than 5 ohms, replace fuel pump relay. If resistance is 5 ohms or more, replace IPM.

NO RESPONSE FROM PCM WITH A NO-START CONDITION

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-1 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition off. Disconnect PCM connectors. PCM is located on left side of engine compartment, near front of battery. (Scheme 87) Inspect connectors for damaged pins, corrosion and loose terminals. Repair connectors necessary. Using a test light connected to ground, probe terminal No. 46 (Orange/Red wire) at PCM C2 harness connector. (Scheme 91) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open in Orange/Red wire between fuse No. 17 (20-amp) in Intelligent Power Module (IPM) on left side of engine compartment, next to battery. (Scheme 87) Also inspect fuse No. 17 in IPM. (Scheme 88)
2. Turn ignition on. Using a test light connected to ground, probe terminal No. 20 (Pink/Gray wire) at PCM C1 harness connector. (Scheme 92) If test light illuminates brightly, power circuits are okay. Go to next step. If test light does not illuminate brightly, repair open fused ignition switch output circuit (Pink/Gray wire) between PCM and IPM.
3. Turn ignition off. Using a test light connected to positive battery voltage, probe terminal No. 10 (Black/Brown wire) at PCM C1 harness connector. Also probe terminal No. 50 (Black/Dark Green wire) at PCM C2 harness connector. If test light illuminates brightly at both terminals, ground circuits are okay. Replace PCM. If test light does not illuminate brightly at one or both terminals, repair open in Black/Brown wire or Black/Dark Green wire between PCM and ground.

Scheme 91

Scheme 92

NO CRANK CONDITION

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-1 under VERIFICATION TESTS to ensure system is functioning properly.

1. Disconnect negative battery cable and wait 2 minutes. Turn engine over by hand to ensure engine is not seized. If engine is not seized, go to next step. If engine is seized, repair mechanical condition preventing engine from cranking.
2. Ensure ignition is off. Reconnect negative battery cable. Disconnect PCM harness connectors. PCM is located on left side of engine compartment, near front of battery. (Scheme 87) Measure resistance between ground and Yellow/Dark Blue wire at terminal No. 76 at PCM C2 harness connector. (Scheme 91) Shift transmission through all gears, from Park to 1st and back. Resistance should be less than 10 ohms when transmission is in Park or Neutral, then switch to more than 10 ohms when transmission is not in Park or Neutral. If resistance is as specified, go to next step. If resistance is not as specified, replace transmission range sensor.
3. Connect voltmeter negative lead to negative battery terminal. Connect voltmeter positive lead to engine block, near negative battery cable grounding point. Crank engine and observe voltmeter. If voltmeter indicates.2 volt or less, go to next step. If voltmeter indicates more than.2 volt, repair poor ground connection or replace ground cable.
4. Remove starter heat shield (if equipped) to gain access to starter solenoid connections. Connect voltmeter negative lead to starter solenoid battery terminal and voltmeter positive lead to positive battery terminal. Crank engine and observe voltmeter. If voltmeter indicates.2 volt or less, go to next step. If voltmeter indicates more than.2 volt, repair poor connection between battery cable and starter solenoid or replace positive battery cable. WARNING: Engine may crank during the following step. Ensure transmission is in Park and parking brake is applied. Keep away from moving engine parts.
5. Ensure ignition is off. Remove starter relay from Intelligent Power Module (IPM) on left side of engine compartment, next to battery. (Scheme 87) Briefly connect a jumper wire between terminals No. 30 and 87 at starter relay socket in IPM. (Scheme 88) If engine cranks, go to next step. If engine does not crank, go to step 9.
6. Connect a test light between ground and terminal No. 86 at starter relay socket in IPM. While observing test light, turn ignition switch to START position. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or high resistance in ignition switch output circuit (Yellow wire). See WIRING DIAGRAMS in appropriate STARTERS article in STARTING & CHARGING SYSTEMS.
7. Turn ignition off. Disconnect PCM harness connectors. Measure resistance of Dark Green/Orange wire between terminal No. 85 at starter relay socket in IPM and terminal No. 31 at PCM C1 harness connector. (Scheme 88)and (Scheme 92). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Green/Orange wire.
8. Reconnect PCM harness connectors. Install a substitute relay in place of starter relay. Attempt to start engine. If engine cranks, replace starter relay. If engine does not crank, replace PCM.
9. Disconnect starter solenoid harness connector. Measure resistance of Yellow/Gray wire between terminal No. 87 at starter relay socket in IPM and terminal No. 1 at starter solenoid harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow/Gray wire.
10. Connect a test light between ground and terminal No. 30 at starter relay socket in IPM. (Scheme 88) If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or high resistance in Red wire between battery and starter relay. Also check fuse No. 9 (40-amp) in IPM.
11. If no other possible causes are remaining, replace starter.

DRIVEABILITY PROBLEMS

Note. The following tests are written specifically for Chrysler's Diagnostic Readout Box (DRBIII(R)) scan tool. A generic scan tool may not be capable of performing all necessary test functions.

START & STALL CONDITION

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-1 under VERIFICATION TESTS to ensure system is functioning properly.

1. Turn ignition on. Using scan tool, check for Diagnostic Trouble Codes (DTC). If no DTCs are present, go to next step. If any DTCs are present, perform appropriate diagnostic test. See SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER article.
2. Using scan tool, read and record Sentry Key Immobilizer Module (SKIM) DTC (fault) messages. If no SKIM DTC messages are present, go to next step. If any SKIM DTC messages are present, a fault exists in anti-theft system. Perform appropriate test. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
3. Turn ignition off. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-99020-S15801066592001061300000) . Connect a fuel pressure gauge to test port on fuel rail. Using scan tool, actuate ASD fuel system test. Allow fuel pressure gauge to stabilize. Stop ASD fuel system activation. Fuel pressure should be 53-63 psi (365-434 kPa). If fuel pressure is less than specified, go to next step. If fuel pressure is more than specified, replace fuel pressure regulator. See «FUEL PRESSURE REGULATOR»(ref-98966-S18316010932001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If fuel pressure is as specified, go to step 6 .
4. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel pump module 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). If fuel pressure is as specified, stop ASD fuel system activation. Release fuel pressure, and repair or replace fuel supply line. If fuel pressure is not as specified, stop ASD fuel system activation and go to next step.
5. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. See «FUEL PUMP MODULE»(ref-98966-S11150099922001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If fuel inlet strainer is plugged, replace fuel pump inlet strainer. If fuel inlet strainer is not plugged, replace fuel pump.
6. Turn ignition off. Release fuel pressure. Disconnect fuel supply line from fuel rail. Install Fuel Line Pressure Test Adapter Hose (6539 for 5/16" fuel lines or 6631 for 3/8" fuel lines) between disconnected fuel line and fuel rail. Remove fuel fill cap. Insert other end of hose into a graduated container suitable for gasoline.
7. Using scan tool, actuate ASD fuel system test for 7 seconds. If fuel volume is .5 pt. (.25L) or more, go to next step. 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. See «FUEL PUMP MODULE»(ref-98966-S11150099922001060700000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article.
8. Turn ignition on. Using scan tool, monitor TP sensor voltage while slowly depressing throttle pedal from idle position to wide open throttle position. If voltage changes smoothly, go to next step. If voltage does not change smoothly, replace TP sensor.
9. Ensure throttle is fully closed and against throttle stop. Using scan tool, read TP sensor voltage. If voltage is .92 volt or less, go to next step. If voltage is more than .92 volt, check for binding throttle linkage. Repair linkage as necessary. If linkage is not binding, replace TP sensor.
10. Turn ignition on. Using scan tool, read Engine Coolant Temperature (ECT) sensor value. If engine coolant temperature is more than 180°F (82°C), allow engine coolant temperature to cool down to 150°F (66°C) before proceeding. If engine coolant temperature is 150°F (66°C) or less, start engine and monitor scan tool until engine coolant temperature reaches 180°F (82°C). If ECT sensor value increases smoothly, go to next step. If ECT sensor value increase is erratic, check for cooling system problems and repair as necessary. If cooling system is okay, replace ECT sensor.
11. Check the following additional items as possible causes for start and stall condition: Check for any technical service bulletins that may apply. Fuel must be free of contamination. Engine exhaust system must be free of restrictions. Engine compression must be within specification. Engine valve timing must be within specification. Engine vacuum must be at least 13 in. Hg with shift selector in Neutral. Throttle body must be free of carbon build-up and dirt. Repair any problems as necessary. If no problems exist, test is complete.

VERIFICATION TESTS

Note. Perform the following verification test only when directed to. Only verification tests that are applicable to diagnostic tests in this article have been included.

SUMMARY

If no faults were found while performing basic diagnostic procedures, see SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If no diagnostic trouble codes are found in self-diagnostics, see TROUBLE SHOOTING - NO CODES - CARAVAN, TOWN & COUNTRY, & VOYAGER article for diagnosis by symptom (i.e., ROUGH IDLE, NO-START, etc.) or intermittent diagnostic procedures.