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Engine Controls - Tests W/codes - 3.3L: Overview Dodge Caravan III

Testing & Diagnostics 23 illustrations ~523 words

CONNECTOR IDENTIFICATION

ConnectorSee Fig.
A/C Pressure Sensor5
Brake Switch6
Camshaft Position Sensor7
Crankshaft Position Sensor8
Data Link Connector9
Downstream Oxygen Sensor10
EGR Solenoid11
Engine Coolant Temperature Sensor12
EVAP Purge Solenoid13
Fuel Pressure Sensor 3.3L CNG14
Fuel Tank Module15
Fuel Temp. Sensor 3.3L CNG16
High Pressure Fuel Shutoff Solenoid 3.3L CNG17
Idle Air Control Motor18
Ignition Coil19
Injector20
Injector Wiring Harness (Injector Side)21
Injector Wiring Harness (PCM Side)22
Knock Sensor23
Leak Detection Pump24
Low Pressure Fuel Shutoff Solenoid 3.3L CNG25
MAP Sensor26
Output Speed Sensor 4-Speed A/T27
Park/Neutral Switch 3-Speed A/T28
Powertrain Control Module (PCM)29
Radiator Cooling Fan Relay30
Speed Control Servo31
Throttle Position Sensor32
Torque Converter Clutch Solenoid 3-Speed A/T33
Transmission Control Module 4-Speed A/T34
Transmission Range Sensor 4-Speed A/T35
Upstream Oxygen Sensor36
Vehicle Speed Sensor 3-Speed A/T45

CONNECTOR IDENTIFICATION DIRECTORY

Scheme 104

Scheme 104
TerminalWire ColorFunction
1Violet/White5-Volt Supply
2Black/Light BlueSensor Ground
3Not UsedNot Used
4Dark BlueSensor Signal

A/C PRESSURE SENSOR CONNECTOR TERMINAL IDENTIFICATION

Scheme 105

Scheme 105
TerminalWire ColorFunction
1White/PinkBrake Switch Sense
2BlackGround
3Yellow/RedS/C On/Off Switch Output
4Dark Blue/RedS/C Brake Switch Output
5White/TanBrakelight Switch Output
6Pink/Dark BlueFused B+

BRAKE SWITCH CONNECTOR TERMINAL IDENTIFICATION

Scheme 106

Scheme 106
TerminalWire ColorFunction
1Orange8-Volt Supply
2Black/Light BlueSensor Ground
3Tan/YellowSensor Signal

CAMSHAFT POSITION SENSOR CONNECTOR TERMINAL ID

Scheme 107

Scheme 107
TerminalWire ColorFunction
1Orange8-Volt Supply
2Black/Light BlueSensor Ground
3Gray/BlackSensor Signal

CRANKSHAFT POSITION SENSOR CONNECTOR TERMINAL ID

Scheme 108

Scheme 108
TerminalWire ColorFunction
3Violet/BrownCCD Bus (+)
4Black/Light GreenGround
5Black/WhiteGround
6Light GreenSCI Receive
7PinkSCI Transmit
11White/BlackCCD Bus (-)
14Pink/Light BlueSCI Receive (TCM)
16PinkFused B+

DATA LINK CONNECTOR TERMINAL IDENTIFICATION

Scheme 109

Scheme 109
TerminalWire ColorFunction
1Black/TanHeater Ground
2Dark Green/OrangeAuto Shutdown Relay Output
3Black/Light BlueSensor Ground
4Tan/WhiteSensor Signal

DOWNSTREAM OXYGEN SENSOR CONNECTOR TERMINAL ID

Scheme 110

Scheme 110
TerminalWire ColorFunction
1Gray/YellowEGR Solenoid Control
2White/BlackFused Ign. Switch Output

EGR SOLENOID CONNECTOR TERMINAL IDENTIFICATION

Scheme 111

Scheme 111
TerminalWire ColorFunction
1Tan/BlackSensor Signal
2Black/Light BlueSensor Ground

ENGINE COOLANT TEMP. SENSOR CONNECTOR TERMINAL ID

Scheme 112

Scheme 112
TerminalWire ColorFunction
1Pink/BlackEVAP Purge Solenoid Control
2White/BlackFused B+

EVAP PURGE SOLENOID CONNECTOR TERMINAL IDENTIFICATION

Scheme 113

Scheme 113
TerminalWire ColorFunction
1Black/Light BlueSensor Ground
2Violet/White5-Volt Supply
3Dark Green/Light BlueSensor Signal

FUEL PRESSURE SENSOR CONNECTOR TERMINAL ID (CNG)

Scheme 114

Scheme 114
TerminalWire ColorFunction
1Dark Green/WhiteFuel Pump Relay Output
2Dark BlueFuel Level Sensor Signal
3Not UsedNot Used
4BlackGround

FUEL TANK MODULE CONNECTOR TERMINAL IDENTIFICATION

Scheme 115

Scheme 115
TerminalWire ColorFunction
1Tan/PinkSensor Signal
2Black/Light BlueSensor Ground

FUEL TEMP. SENSOR CONNECTOR TERMINAL ID (CNG)

Scheme 116

Scheme 116
TerminalWire ColorFunction
1BlackSolenoid Ground
2Dark Green/WhiteFuel Pump Relay Output

HIGH PRESSURE FUEL SHUTOFF SOLENOID CONNECTOR TERMINAL IDENTIFICATION (CNG)

Scheme 117

Scheme 117
TerminalWire ColorFunction
1Violet/BlackIAC Motor No. 4 Driver
2Brown/WhiteIAC Motor No. 3 Driver
3Yellow/BlackIAC Motor No. 2 Driver
4Gray/RedIAC Motor No. 1 Driver

IDLE AIR CONTROL MOTOR CONNECTOR TERMINAL ID

Scheme 118

Scheme 118
TerminalWire ColorFunction
1Red/YellowIgnition Coil No. 3 Driver
2GrayIgnition Coil No. 1 Driver
3Dark Blue/TanIgnition Coil No. 2 Driver
4Dark Green/OrangeAuto Shutdown Relay Output

IGNITION COIL CONNECTOR TERMINAL ID

Scheme 119

Scheme 119
TerminalWire ColorFunction
1Dark Green/OrangeAuto Shutdown Relay Output
2 (1)White/Dark BlueInjector No. 1 Driver
2 (1)TanInjector No. 2 Driver
2 (1)Yellow/WhiteInjector No. 3 Driver
2 (1)Light Blue/BrownInjector No. 4 Driver
2 (1)GrayInjector No. 5 Driver
2 (1)Brown/Dark BlueInjector No. 6 Driver
(1) Connectors are same for all injectors except wire color at terminal No. 2. Listed are wire colors for specified injector driver at terminal No. 2.
(1)Connectors are same for all injectors except wire color at terminal No. 2. Listed are wire colors for specified injector driver at terminal No. 2.

INJECTOR CONNECTOR TERMINAL IDENTIFICATION

Scheme 120

Scheme 120
TerminalWire ColorFunction
1Dark Green/OrangeAuto Shutdown Relay Output
2Violet/White5-Volt Supply
3White/Dark BlueInjector No. 1 Driver
4TanInjector No. 2 Driver
5Yellow/WhiteInjector No. 3 Driver
6Light Blue/BrownInjector No. 4 Driver
7Dark Blue/TanIgnition Coil No. 2 Driver
8Red/YellowIgnition Coil No. 3 Driver
9GrayIgnition Coil No. 1 Driver
10Dark Green/RedMAP Sensor Signal
11Tan/BlackCoolant Temp. Sensor Signal
12GrayInjector No. 5 Driver
13Brown/Dark BlueInjector No. 6 Driver
14Black/Light BlueSensor Ground

INJECTOR WIRING HARNESS CONNECTOR (INJECTOR SIDE) TERMINAL IDENTIFICATION

Scheme 121

Scheme 121
TerminalWire ColorFunction
1Dark Green/OrangeAuto Shutdown Relay Output
2Violet/White5-Volt Supply
3White/Dark BlueInjector No. 1 Driver
4TanInjector No. 2 Driver
5Yellow/WhiteInjector No. 3 Driver
6Light Blue/BrownInjector No. 4 Driver
7Dark Blue/TanIgnition Coil No. 2 Driver
8Red/YellowIgnition Coil No. 3 Driver
9GrayIgnition Coil No. 1 Driver
10Dark Green/RedMAP Sensor Signal
11Tan/BlackCoolant Temp. Sensor Signal
12GrayInjector No. 5 Driver
13Brown/Dark BlueInjector No. 6 Driver
14Black/Light BlueSensor Ground

INJECTOR WIRING HARNESS CONNECTOR (PCM SIDE) TERMINAL IDENTIFICATION

Scheme 122

Scheme 122
TerminalWire ColorFunction
1Black/Light BlueSensor Ground
2Dark Blue/Light GreenSensor Signal

KNOCK SENSOR CONNECTOR TERMINAL IDENTIFICATION

Scheme 123

Scheme 123
TerminalWire ColorFunction
1Yellow/BlackPump Switch Sense
2White/Dark GreenSolenoid Control
3White/BlackFused Ign. Switch Output
4Not UsedNot Used

LEAK DETECTION PUMP CONNECTOR TERMINAL IDENTIFICATION

RADIATOR COOLING FAN RELAY CONNECTOR TERMINAL IDENTIFICATION

TerminalWire ColorFunction
1BlackGround
2Light Green/Dark BlueRad Fan Relay Control
3Dark GreenRad Fan Relay Output
4GrayFused B+

RADIATOR COOLING FAN RELAY CONNECTOR TERMINAL ID

SPEED CONTROL SERVO CONNECTOR TERMINAL IDENTIFICATION

TerminalWire ColorFunction
1Tan/RedS/C Vacuum Solenoid Control
2Light Green/RedS/C Vent Solenoid Control
3Dark Blue/RedS/C Brake Switch Output
4BlackGround

SPEED CONTROL SERVO CONNECTOR TERMINAL IDENTIFICATION

Scheme 124

Scheme 124: THROTTLE POSITION SENSOR CONNECTOR TERMINAL ID
TerminalWire ColorFunction
1Black/Light BlueSensor Ground
2Orange/Dark BlueSensor Signal
3Violet/White5-Volt Supply

THROTTLE POSITION SENSOR CONNECTOR TERMINAL ID

Scheme 125

Scheme 125: IDENTIFYING TORQUE CONVERTER CLUTCH SOLENOID CONNECTOR TERMINALS (3-SPEED A/T)

Scheme 126

Scheme 126: IDENTIFYING TRANSMISSION CONTROL MODULE CONNECTOR TERMINALS 4-SPEED A/T)

TEST NTC-4A - CHECKING COOLANT SENSOR CALIBRATION & RADIATOR FAN OPERATION

Note. Perform NTC-1A or NTC-3A before proceeding. Following test procedure is invalid if thermostat is stuck open, closed or removed.

  1. Check thermostat operation. If thermostat operates correctly, go to next step. If thermostat does not operate correctly, replace thermostat. Perform TEST VER-2A.
  2. Ensure ignition is on with engine off. Ensure engine coolant temperature is less than 160°F (71°C).
  3. Using scan tool, read Engine Coolant Temperature (ECT) sensor value. Using temperature probe, check temperature on cylinder block, near engine coolant temperature sensor. Engine coolant temperature sensor is located near thermostat housing and contains a Black/Light Blue wire and Tan/Black wire in the connector.
  4. If ECT sensor value on scan tool is not within 15°F (-9°C) of temperature reading on temperature probe, replace engine coolant temperature sensor. Perform TEST VER-2A. If ECT sensor value on scan tool is within 15°F (-9°C) of temperature reading on temperature probe, go to next step.
  5. Start engine and warm engine until engine coolant temperature is greater than 180°F (82°C). Using temperature probe, check temperature on cylinder block, near engine coolant temperature sensor. Compare ECT sensor value on scan tool with temperature reading on temperature probe.
  6. If ECT sensor value on scan tool does not stay within 15°F (-9°C) of temperature reading on temperature probe at all times, replace engine coolant temperature sensor. Perform TEST VER-2A. If ECT sensor value on scan tool stays within 15°F (-9°C) of temperature reading on temperature probe at all times, go to next step.
  7. Operate engine until radiator fan operates or engine coolant temperature reaches 220°F (104°C). If cooling fan does not operate, repair cooling fan as necessary. See appropriate SPECIFICATIONS & ELECTRIC COOLING FANS article in the ENGINE COOLING section. If cooling fan operates, engine coolant temperature sensor and radiator fan are operating properly. Test is complete.