Driveability - Gas - Non-Dtc Based Diagnostics: Overview Dodge Challenger III facelift

Scheme 21

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

Scheme 22

Scheme 23

Scheme 24

1. GENERATOR FULL FIELD TEST NOTE: Diagnose and repair any generator sense or field control circuit DTCs before proceeding with this test. Start the engine and allow it to reach operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. With the scan tool, perform the Generator Full Field test. Follow the instructions displayed on the scan tool. Monitor the system (battery) voltage and the generator sense voltage on the scan tool while performing the test. NOTE: With the engine running, the difference between the system (battery) voltage and the generator sense voltage should be below 2 Volts. NOTE: With the generator field fully actuated, the system (battery) voltage should be above 14.0 Volts. NOTE: With the generator field actuated off, the system (battery) voltage should be below 13.0 Volts, and eventually drop as battery load is increased. Did the system voltage change as described above during the Generator Full Field test? Yes Test complete. No Go To 2 .
2. CHARGING SYSTEM INSPECTION Inspect and test the battery in accordance with the Service Information. Inspect the generator drive belt for proper alignment and adjustment. Inspect the vehicle for aftermarket accessories that may exceed the generator system output. Inspect the fuses in the PDC. If an open fuse is found, use the wire diagram/schematics as a guide and inspect the wiring and connectors for a damaged or shorted circuit. Were any problems found? Yes Repair as necessary. No Go To 3 .
3. BATTERY POSITIVE (+) CIRCUIT HIGH RESISTANCE NOTE: Make sure all testing equipment and cables are clear of any engine parts before starting the engine. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Measure the voltage between the B (+) Terminal at the Generator and the Battery Positive (+) Post. Is the voltage below 0.25 Volt? Yes Go To 4 . No Repair the battery positive (+) circuit between the generator and battery for high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
4. GENERATOR CASE GROUND HIGH RESISTANCE NOTE: Make sure all testing equipment and cables are clear of any engine parts before starting the engine. Start the engine. Measure the voltage between the Generator case and the Battery Negative (-) post. Is the voltage below 0.25 Volt? Yes Go To 5 . No Repair the Generator Case ground for high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
5. (A209) FUSED B(+) CIRCUIT HIGH RESISTANCE Turn the ignition off. Using a Voltmeter, perform a voltage drop test by probing the battery positive (+) terminal and the appropriate terminal(s) of the PCM. Make sure the Voltmeter leads are connected so that positive polarity is displayed on the voltmeter. Start the engine. Is the voltage below 0.25 Volt? Yes Go To 6 . No Repair the (A209) Fused B(+) circuit(s) for high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
6. (A804) GENERATOR SENSE CIRCUIT HIGH RESISTANCE Turn the ignition off. Using a voltmeter, perform a voltage drop test by backprobing the (A804) Generator Sense circuit at the Generator harness connector and the PCM C2 harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. Start the engine. Is the voltage below 0.25 Volt? Yes Go To 7 . No Repair the (A804) Generator Sense circuit for high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
7. GENERATOR Turn the ignition off. Disconnect the Generator harness connector. Connect a 12-Volt test light connected between ground and the (K20) Gen Field Control circuit in the Generator harness connector. Turn the ignition on. With the scan tool, actuate the Alternator Field Control State to toggle. NOTE: The test light should toggle on and off with the actuation. NOTE: If a DTC is active, the actuation test may not be allowed by the PCM. If may be necessary to clear DTCs before starting the actuation. Does the test light illuminate on and off with the actuation? Yes Replace the Generator in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Go To 8 .
8. (K20) GEN FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE Turn the ignition off. Disconnect the PCM C2 harness connector. Turn the ignition on. Measure the voltage of the (K20) Gen Field Control circuit in the Generator harness connector. Is there any voltage present? Yes Repair the (K20) Gen Field Control circuit for a short to voltage. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Go To 9 .
9. (K20) GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND Turn the ignition off. Measure the resistance between ground and the (K20) Gen Field Control circuit in the Generator harness connector. Is the resistance below 100 Ohms? Yes Repair the (K20) Gen Field Control circuit for a short to ground. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Go To 10 .
10. (K20) GEN FIELD CONTROL CIRCUIT OPEN OR HIGH RESISTANCE Measure the resistance of the (K20) Gen Field Control circuit between the Generator harness connector and the appropriate terminal of the PCM C2 harness connector. Is the resistance below 5.0 Ohms? Yes Go To 11 . No Repair the (K20) Gen Field Control circuit for an open circuit or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
11. CHECKING THE PCM POWER AND GROUND CIRCUITS Inspect the PCM power and ground circuits. Were any problems found? Yes Repair the PCM power and ground circuit(s) as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Go To 12 .
12. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Generator and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Perform any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Refer to «MODULE, POWERTRAIN CONTROL, REMOVAL»(ref-489300-S42869345482012072600000) . Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .

Scheme 25

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

COOLING FAN MODES OF OPERATION

The two speed cooling fan system uses three relays to control the cooling fan operation. These are the Series-Parallel Fan Relay, Lo-Hi Fan Relay and Hi-Med. Fan Relay. During low speed mode, the cooling fan and cooling fan resistor operate in series, splitting the 12 Volt source between the resistor and the cooling fan motor. During high speed mode, the cooling fan motor and resistor operate in parallel to one another, with each receiving a separate 12 Volt source.

During low speed mode: The PCM grounds the (N201) Fan Relay Control circuit, closing the relay to connect the (A16) Cooling Fan 12 Volt Supply circuit to the (N23) Cooling Fan Motor 1 Output circuit. The (N23) Cooling Fan Motor 1 Output circuit supplies 12 Volts DC to cooling fan resistor. Current flows through the resistor to the (N210) Cooling Fan Lo-Hi Control circuit. The current passes through the Lo-Hi Fan Relay to the (N24) Cooling Fan Motor 2 Output circuit and on to Cooling Fan Motor. The (Z903) Ground circuit provides the ground path for the Cooling Fan series circuit.

During High speed mode: The PCM grounds the (N201) Fan Relay Control circuit and the (N112) Fan Relay Control circuit, closing all three Cooling Fan Relays. The (A16) Cooling Fan 12 Volt Supply circuit connects to the (N24) Cooling Fan Motor 2 Output circuit through the Series-Parallel Fan Relay and provides 12 Volts to Cooling Fan Motor 2. The (Z903) Ground circuit provides the ground for Cooling Fan Motor 2. The (A16) Cooling Fan 12 Volt Supply circuit connects to the (N23) Cooling Fan Motor 1 Output circuit through the Hi-Med. Fan Relay and provides 12 Volts through the cooling fan resistor. The (N210) Cooling Fan Lo-Hi Control circuit connects to the (Z903) Ground circuit through the Lo-Hi Fan Relay to provide the ground path for the cooling fan resistor.

Scheme 26

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Scheme 28

Scheme 29

1. RADIATOR FAN OPERATION NOTE: Diagnose and repair any Cooling Fan Relay control circuit DTCs before proceeding with this test. Turn the ignition on, engine not running. Using a scan tool, actuate the low speed fan. Using a scan tool, actuate the high speed fan. NOTE: During high speed actuation the Cooling Fan Motor is easily audible. Does the fan operate in both speeds? Yes The cooling fan is operating normal at this time. Perform the INTERMITTENT CONDITION test procedure. Refer to «INTERMITTENT CONDITION»(ref-489378-S12445621442012072600000) or «INTERMITTENT CONDITION»(ref-489385-S21404612872012072600000) . No, the cooling fan does not operate for either speed Go To 2 . No, only the low speed is operating Go To 8 . No, only the high speed is operating Go To 10 .
2. RADIATOR FAN BATTERY SUPPLY CIRCUIT Stop the actuation. Remove the Radiator Fan Series/Parallel Relay from the PDC. Using a 12-Volt test light connected to ground, probe the Battery Feed circuit at the relay connector (terminal 30). Is the test light illuminated and bright? Yes Go To 3 . No Inspect the 50 amp Radiator Fan fuse. If the fuse is ok, replace the Powertrain Distribution Center (PDC). If the fuse is open, Go To 5 . Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
3. EXCESSIVE RESISTANCE IN THE (N210) CIRCUIT Turn the ignition off. Measure the resistance of the (N210) circuit from the Cooling Fan Module harness connector to the Radiator Fan Series/Parallel Relay connector (terminal 87). Is the resistance below 5.0 Ohms? Yes Go To 4 . No Repair the (N210) circuit for an open or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
4. CHECK THE (Z903) GROUND CIRCUIT Using a 12-Volt test light connected to 12 Volts, probe the (Z903) Ground circuit at the Cooling Fan Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Replace the Cooling Fan Module in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Repair the (Z903) Ground circuit for an open or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
5. (N210) CIRCUIT SHORTED TO GROUND Turn the ignition off. Disconnect the Cooling Fan Module harness connector. Measure the resistance between ground and the (N210) circuit at the Cooling Fan Module harness connector. Is the resistance below 10k Ohms? Yes Repair the short to ground in the (N210) circuit. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Go To 6 .
6. (N24) CIRCUIT SHORTED TO GROUND Remove the Radiator Fan Medium/High Relay and the Radiator Fan Low/High Relay from the PDC. Measure the resistance between ground and the (N24) circuit at the Cooling Fan Module harness connector. Is the resistance below 10k Ohms? Yes Repair the short to ground in the (N24) circuit. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Go To 7 .
7. (N23) CIRCUIT SHORTED TO GROUND Measure the resistance between ground and the (N23) circuit at the Cooling Fan Module harness connector. Is the resistance below 10k Ohms? Yes Repair the (N23) circuit for an open or short to ground. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Replace the Cooling Fan Module in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
8. RADIATOR FAN BATTERY SUPPLY CIRCUIT Stop the actuation. Remove the Radiator Fan Series/Parallel Relay from the PDC. Using a 12-Volt test light connect to ground, probe the Battery Feed circuit at the relay connector (terminal 30). Is the test light illuminated and bright? Yes Go To 9 . No Replace the Powertrain Distribution Center (PDC) in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
9. CHECK RADIATOR FAN SERIES/PARALLEL RELAY Connect a jumper across terminal 30 and terminal 87 at the Radiator Fan Series/Parallel Relay connector in the PDC. Does the Cooling Fan operate with the jumper in place? Yes Replace the Radiator Fan Series/Parallel Relay. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Replace the Powertrain Distribution Center (PDC) in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
10. RADIATOR FAN BATTERY SUPPLY CIRCUIT Stop the actuation. Remove the Radiator Fan Medium/High Relay from the PDC. Using a 12-Volt test light connect to ground, probe the Battery Feed circuit at the relay connector (terminal 30). Is the test light illuminated and bright? Yes Go To 11 . No Replace the Powertrain Distribution Center (PDC) in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
11. EXCESSIVE RESISTANCE IN THE (N24) CIRCUIT Turn the ignition off. Disconnect the Cooling Fan Module harness connector. Measure the resistance of the (N24) circuit between the Cooling Fan Module harness connector and terminal 87 of the Radiator Fan Medium/High Relay connector. Is the resistance below 5.0 Ohms? Yes Go To 12 . No Repair the (N24) circuit for an open or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
12. EXCESSIVE RESISTANCE IN THE (N23) CIRCUIT Remove the Radiator Fan Low/High Relay in the PDC. Measure the resistance of the (N23) circuit between the Cooling Fan Module harness connector and terminal 30 of the Radiator Fan Low/High Relay connector. Is the resistance below 5.0 Ohms? Yes Go To 13 . No Repair the (N23) circuit for an open or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
13. EXCESSIVE RESISTANCE IN THE (N210) RAD FAN RELAY OUTPUT CIRCUIT Measure the resistance of the (N210) circuit between the Cooling Fan Module harness connector and terminal 87A of the Radiator Fan Low/High Relay connector. Is the resistance below 5.0 Ohms? Yes Go To 14 . No Repair the (N210) circuit for an open or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .
14. CHECK THE (Z903) GROUND CIRCUIT Using a 12-Volt test light connected to 12 Volts, probe the (Z903) Ground circuit at the Cooling Fan Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Replace the Cooling Fan Module in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) . No Repair the (Z903) Ground circuit for an open. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-489378-S12744453532012072600000) or «POWERTRAIN VERIFICATION TEST»(ref-489385-S17358983152012072600000) .

Scheme 30

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .