Engine Controls - Tests W/codes - 2.5l Dodge Dakota I

INTRODUCTION

If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, proceed with self-diagnostics. If no fault codes or only pass codes are present after entering self-diagnostics, proceed to H - GAS TESTS W/O CODES article for diagnosis by symptom (i.e. ROUGH IDLE, NO START, etc.).

MODEL IDENTIFICATION

VEHICLE BODY IDENTIFICATION

Note. Fault code charts may contain references to body types not covered in this article.

SYSTEM DIAGNOSIS

The self-diagnostic capabilities of this system, if properly utilized, can simplify testing. The Single-Board Engine Controller (SBEC) monitors several different engine control system circuits.

If a problem is sensed with a monitored circuit, a fault code is stored in the SBEC, the CHECK ENGINE light illuminates, and SBEC enters limp-in mode. In limp-in mode, SBEC compensates for component failure by substituting information from other sources. This allows vehicle operation until repairs can be made.

Once fault codes are known, refer to FAULT CODES table in this article to determine the questionable circuit. Test circuits and repair or replace components as required. If problem is repaired or ceases to exist, the SBEC cancels that fault code after approximately 50 ignition on-off cycles. To clear fault codes, see CLEARING FAULT CODES in this article.

A specific fault code is the result of a particular system failure, but it DOES NOT indicate that cause of failure is necessarily within system. The fault code DOES NOT condemn any specific component; it pinpoints a probable malfunctioning area.

Hard Failures

Hard failures cause CHECK ENGINE light to illuminate and remain on until the malfunction is repaired. If light comes on and remains on (light may flash) during vehicle operation, cause of malfunction must be determined using diagnostic (code) charts. If a sensor fails, SBEC will use a substitute value in its calculations, allowing engine operation in limp-in mode. In this condition, vehicle will run but driveability may be poor.

Note. A start counter (key counter) appears at bottom of fault message on DRB-II to show number of engine starts since fault code last occurred. This helps determine if fault is intermittent. As an example, if DRB-II displays 0 STARTS SINCE ERS, it indicates zero engine starts since fault occurred, and fault code is a hard failure. If start counter (key counter) shows more than zero engine starts since fault last occurred, then fault code is an intermittent failure.

Intermittent Failures

Intermittent failures may cause CHECK ENGINE light to flicker or illuminate and go out after the intermittent fault goes away. However, the corresponding fault code will be retained in SBEC memory.

If related fault does not reoccur within a certain time frame, fault code will be erased from SBEC memory. Intermittent failures can be caused by a defective sensor, connector, or wiring-related problems. See INTERMITTENTS in H - GAS TESTS W/O CODES article.

DIAGNOSTIC PROCEDURE

To obtain fault codes, see RETRIEVING FAULT CODES in this article. If fault codes are NOT present and/or Diagnostic Readout Box II (DRB-II) is used, proceed to one of the following tests.

1. Go to NO START TEST 1A (NS-1A) chart if a no-start condition exists, or engine stalls after start-up. Perform indicated VERIFICATION PROCEDURE chart after repairs. Ensure charts apply to engine being tested.
2. Go to DRIVEABILITY TEST 1A (DR-1A) chart if engine runs but has performance problems. Perform indicated VERIFICATION PROCEDURE chart after repairs. Ensure charts apply to engine being tested.

Note. When using trouble shooting charts for diagnosis, DO NOT skip any steps in chart, or incorrect diagnosis may result.

Before proceeding with diagnosis, the following precautions must be followed

1. Vehicle must have a fully charged battery, and functional charging system.
2. Probe SBEC connector from pin side. DO NOT backprobe SBEC connector.
3. DO NOT cause short circuits when performing electrical tests. This will set additional fault codes, making diagnosis of original problem more difficult.
4. DO NOT use a test light in place of a voltmeter.
5. When checking for spark, ensure coil wire is NO more than 1/4" from ground. If coil wire is more than 1/4" from ground, damage to vehicle electronics and/or SBEC may result.
6. DO NOT prolong testing of fuel injectors, or engine may hydrostatically (liquid) lock.
7. Always repair lowest fault code number (CHECK ENGINE light), or first fault displayed (DRB-II) first.
8. Always perform VERIFICATION PROCEDURE test after repairs are made.
9. Always disconnect DRB-II after use.
10. Always disconnect DRB-II before charging battery.

RETRIEVING FAULT CODES

Note. Manufacturer recommends using DRB-II (Diagnostic Readout Box-II, C-4805) to diagnose the system. CHECK ENGINE light function can be used, but has limited diagnostic usage. Unable to locate this exact procedure. Chuck said it was okay to leave in.

Check Engine Light Method

1. Start engine (if possible). Move transmission shift lever through all gear positions, ending in Park. Turn A/C switch on, then off (if equipped).
2. Turn engine off. Without starting engine again, turn ignition on, off, on, off, and on. Record 2-digit fault codes as displayed by the flashing CHECK ENGINE light.
3. For example, Code 23 is displayed as flash, flash, 4-second pause, flash, flash, flash. After a slightly longer pause, other codes stored are displayed in numerical order.
4. Once CHECK ENGINE light begins to flash fault codes, it cannot be stopped. If you lose count, it will be necessary to start over. Code 55 indicates end of fault code display.
5. Refer to «FAULT CODES»(/dodge/dakota/i-1987-1996/remont/testing-diagnostics/#engine-controls-tests-wcodes-25l) table to translate fault code number to a system fault description (display on DRB-II). Once fault code description is obtained, refer to appropriate NO START TEST 1A (NS-1A) or DRIVEABILITY TEST 1A (DR-1A) trouble shooting chart for additional testing procedures.
6. As an example, a 3.0L engine starts and runs, but has a driveability problem, and CHECK ENGINE light indicates a Code 14. Refer to «FAULT CODES»(/dodge/dakota/i-1987-1996/remont/testing-diagnostics/#engine-controls-tests-wcodes-25l) table to translate fault code number to a system fault description (display on DRB-II).
7. When system fault description (display on DRB-II) is obtained, refer to appropriate DRIVEABILITY TEST 1A (DR-1A) trouble shooting chart, since vehicle has a driveability problem, for more testing procedures. Select fault message and corresponding test from table, and proceed to appropriate trouble shooting chart. Test procedure may vary depending whether fault code is a hard or intermittent failure.

Note. When using trouble shooting charts for diagnosis, DO NOT skip any steps in chart, or incorrect diagnosis may result.

Note. The DRB-II can also be used to perform the following: display the state or values of sensors, inputs/outputs and components, allow various outputs such as valves and hydraulics to be tested, and reset Emission Maintenance Reminder (EMR) functions. See OPERATING MODES and EMISSION MAINTENANCE REMINDER (EMR) in this article.

Scheme 8

Scheme 9

Scheme 10

1. Turn ignition off. Attach DRB-II Tester (C-4805) to diagnostic connector. DIAGNOSTIC CONNECTOR LOCATIONS (1) Application Location Caravan, Voyager In Engine Compartment, Near SBEC Dakota In Engine Compartment, On Right Corner Of Firewall (1) (Scheme 8)-5.
2. Start engine (if possible). Move transmission shift lever through all positions, ending in Park. Turn A/C switch on, then off (if equipped). Turn engine off. Without starting engine again, turn ignition on. DO NOT touch keypad on DRB-II during power-up sequence, or an error will result. The copyright date and diagnostic program will be displayed briefly.
3. If DRB-II screen is blank, or if an error message appears, proceed to «DRB-II PROBLEMS & ERROR MESSAGES»(/dodge/dakota/i-1987-1996/remont/testing-diagnostics/#engine-controls-tests-wcodes-25l) in this article. The following are possible error messages that may appear: BAD FRAMING, BAD OP CODE, CARTRIDGE ERROR, COMMAND REJECTED, HIGH BATTERY, KEYPAD TEST FAILURE, LOW BATTERY, NO RESPONSE or RAM TEST FAILURE.
4. After a few seconds, display will change to read as follows: DRB-II, 1) VEHICLES TESTED, or 2) HOW TO USE. Press ENTER button immediately. Press the down arrow twice. Display will now read as follows: DRB-II, 2) HOW TO USE, 3) CONFIGURE, and 4) SELECT SYSTEM.
5. Select No. 4 (SELECT SYSTEM) to enter the diagnostic system. Display will read as follows: SELECT SYSTEM, 1) ENGINE, and 2) TRANSMISSION. Select No. 1 (ENGINE) to enter the engine system part of the DRB-II program. Display will change to read as follows: 1991 XX, XXXX EMISSIONS, AUTOMATIC TRANS, SBEC XX,#XXXX-A. NOTE: Display may vary slightly depending on engine package being diagnosed.
6. After a few seconds, display will change to read as follows: AIR COND, 1) WITH A/C, and 2) WITHOUT A/C. Press ENTER button to change display immediately. Select No. 1 or No. 2 as appropriate for vehicle being tested.
7. Display will now read as follows: ENGINE SYSTEM, 1) FUEL/IGNITION, and 2) CHARGING. Select No. 1 (FUEL/IGNITION) to bring up menu of test categories for the fuel/ignition system. Display will change to read as follows: FUEL/IGN MENU, 1) SYSTEM TEST, and 2) READ FAULTS.
8. Press the down arrow 3 times to view rest of menu. Display will read as follows: FUEL/IGN MENU, 3) STATE DISPLAY, 4) ACTUATOR TEST, and 5) ADJUSTMENTS. To read fault codes, select No. 2 (READ FAULTS).
9. If no fault code exists, display will read as follows: NO FAULTS DETECTED. If fault codes exist, display will show number of faults detected, such as 1 of 3 faults, and fault message. This is the fault counter. Below the fault message, the start counter (key counter) will list number of starts since fault code was set.
10. The start counter (key counter) helps to determine if fault is intermittent. As an example, if DRB-II displays 0 STARTS SINCE ERS, this indicates zero engine starts since fault occurred, and fault code is a hard failure. If start counter (key counter) on DRB-II shows more than zero engine starts since fault last occurred, fault code is an intermittent failure.
11. If more than one fault code exists, press the down arrow to display next fault code. All fault codes must be read before fault codes can be erased. Once fault codes are obtained, refer to appropriate NO START TEST 1A (NS-1A) or DRIVEABILITY TEST 1A (DR-1A) trouble shooting chart.

Note. When using trouble shooting charts for diagnosis, DO NOT skip any steps in chart, or incorrect diagnosis may result.

CLEARING FAULT CODES

Note. It will be necessary to place DRB-II in the FUEL/IGN MENU to erase fault codes. This menu is obtained when retrieving fault codes. See DRB-II METHOD under RETRIEVING FAULT CODES .

1. Once fault codes have been read and DRB-II is in FUEL/IGN MENU, press the down arrow. Display will read as follows: ERASE FAULTS, 1) DON'T ERASE, and 2) ERASE. Press the down arrow.
2. Display will ask you if you are sure you want to erase fault codes. Press ENTER button to erase fault codes. DRB-II will display FAULTS ERASED message.

* PLEASE READ THIS FIRST *

Note. Actuator, sensor, solenoid and switch tests available on DRB-II will vary depending on engine, transaxle and emission packages.

STATE DISPLAY MODE

The SBEC can only recognize high and low states on switch circuits. SBEC cannot tell the difference between switch position versus an open or short circuit, or a defective switch.

If a change is noted, it is assumed entire switch circuit to the SBEC is operating correctly. The following information can be selected from the state display mode: module, sensor, inputs/outputs, monitoring of system, and custom display.

Module Info

When module information is selected from STATE DISPLAY mode, information about the SBEC, such as, engine application, transmission application and identification number can be obtained. Information can be used to verify proper SBEC application.

Sensor

When sensor information is selected from STATE DISPLAY mode, information is provided about engine operation through various sensors and engine controls depending on engine and model application. The following information may be displayed.

1. Added Adaptive Fuel
2. Adaptive Fuel Factor
3. Air Idle Speed (AIS) Motor Position
4. Barometric Pressure
5. Battery Temperature
6. Battery Voltage
7. Charging System Goal
8. Charge Temperature
9. Charge Temperature Sensor Reading
10. Coolant Temperature
11. Coolant Temperature Sensor Reading
12. Distributorless Ignition System (DIS) Status
13. Engine Speed
14. Fault No. 1 Key-On Info
15. Fault No. 2 Key-On Info
16. Fault No. 3 Key-On Info
17. Knock Sensor Signal
18. Manifold Absolute Pressure Sensor Vacuum Reading
19. Manifold Absolute Pressure Sensor Voltage Reading
20. Minimum Idle Speed
21. Minimum Throttle Position Sensor Voltage
22. Module Spark Advance
23. Overall Knock Retard
24. Oxygen Sensor State
25. Oxygen Sensor Voltage
26. Theft Alarm Status
27. Throttle Body Temperature
28. Throttle Opening
29. Throttle Position Sensor Voltage
30. Total Spark Advance
31. Speed Control Status
32. Speed Control Target
33. Vehicle Speed

Inputs/Outputs

When input/output information is selected from state display mode, information is provided about component operation through various lights, relays, solenoids and switches depending on engine and model application. The following information may be displayed.

1. A/C Clutch Relay
2. A/C Switch
3. Air Switching Solenoid
4. Auto Shutdown (ASD) Relay
5. Brake Switch
6. CHECK ENGINE Light
7. Closed Throttle Switch
8. EGR Solenoid
9. Emission Maintenance Reminder (EMR) Light
10. Idle Switch
11. Lockup Solenoid
12. Overdrive Override
13. Overdrive Solenoid
14. Park Neutral Switch (A/T Models)
15. Part Throttle Unlock (PTU) A/T Only
16. Purge Control Solenoid
17. Radiator Fan Relay
18. Shift Indicator Light
19. Speed Control On/Off Switch
20. Speed Control Resume
21. Speed Control Setting
22. Speed Control Vacuum Solenoid
23. Speed Control Vent Solenoid

Monitors

When monitor information is selected from STATE DISPLAY mode, information is provided about various systems or components as they are monitored depending on engine and model application. The following possible information may be displayed.

1. Adaptive Memory
2. Engine RPM
3. Fuel Control
4. Fuel Mileage
5. Interrogator
6. Knock Retard
7. No Start
8. Secondary Indicators
9. Spark Advance

Custom Display

When custom display is selected, information can be changed to what the technician wants to monitor.

ACTUATOR TEST MODE

Actuator test mode is used to check operation of output circuits of devices the SBEC cannot recognize. The following, depending on engine and model application, can be activated in actuator test mode to ensure component operation: relays, solenoids and various components. The following are information or components that may be accessed through actuator test mode.

1. A/C Clutch Relay
2. Air Idle Speed (AIS) Motor
3. Air Switch Solenoid
4. Alternator Field
5. ASD (Auto Shutdown) Relay
6. ASD (Auto Shutdown) System
7. CHECK ENGINE Light
8. EGR Solenoid
9. Emission Maintenance Reminder (EMR) Light
10. Fuel Injector
11. Ignition Coil
12. Overdrive Solenoid
13. Part Throttle Unlock (PTU) A/T Only
14. Purge Solenoid
15. Radiator Fan Relay
16. Shift Indicator Light (M/T Only)
17. Solenoid/Relays
18. Speed Control Servo Solenoids
19. Stop All Tests
20. Tachometer Output

ADJUSTMENTS MODE

In adjustments mode, fault codes can be erased and memory can be reset for the adaptive fuel, minimum TPS and all values. If SBEC is replaced, the Emission Maintenance Reminder (EMR) light can be reset, EMR light memory can be checked, and EMR mileage can be transferred.

BAD FRAMING

If message is displayed, replace cartridge with later version.

BAD OP CODE

If message is displayed, replace cartridge with later version.

BLANK MESSAGE

1. Connect DRB-II to a different vehicle. If message screen is still blank, DRB-II or adapter cable are faulty. Substitute to determine faulty component. If message screen is not blank, DRB-II and adapter cable are functioning properly.
2. Inspect diagnostic connector for proper wire placement, damaged terminals or pushed out pins. Repair as necessary. If connector is okay, check resistance between Black or Black/White wire of diagnostic connector and ground using an ohmmeter. (Scheme 8)
3. If resistance is less than 10 ohms, repair open circuit in Black or Black/White wire between diagnostic connector and 60-pin connector on the SBEC. See SBEC LOCATIONS table for component location.

SBEC LOCATIONS

CARTRIDGE ERROR

If message is displayed, replace DRB-II cartridge and proceed with diagnostics.

COMMAND REJECTED

If message is displayed, replace cartridge with later version.

HIGH BATTERY

If message is displayed, connect DRB-II to a different vehicle. If message still exists, DRB-II or adapter cable are faulty. Substitute to determine faulty component. If message is not displayed, DRB-II and adapter cable are functioning properly. Repair charging system.

KEYPAD TEST FAILURE

Ensure ignition is off. DO NOT touch keypad on DRB-II. Turn ignition on. If DRB-II displays KEYPAD TEST FAILURE, replace DRB-II. If KEYPAD TEST FAILURE message is not displayed, proceed with diagnostics.

LOW BATTERY

If message is displayed, connect DRB-II to a different vehicle. If message still exists, DRB-II or adapter cable are faulty. Substitute to determine faulty component. If message is not displayed, DRB-II and adapter cable are functioning properly. Repair charging system.

NO RESPONSE

Note. No response may be caused by one of the following: DRB-II is connected to wrong diagnostic connector, ignition is off, defective adapter cable, cartridge or DRB-II, defective SBEC, connector or wiring.

Scheme 11

1. Ensure DRB-II is connected to proper diagnostic connector. (Scheme 9)-5. Ensure ignition is turned on and all wiring connections are secure.
2. Turn ignition off. Disconnect DRB-II from diagnostic connector. Disconnect 60-pin connector from SBEC. See SBEC LOCATIONS table for component location. Using ohmmeter, check resistance between Pink wire terminal on diagnostic connector and pin No. 25 (Pink wire) on 60-pin connector. (Scheme 8)and (Scheme 12).
3. If resistance is greater than 10 ohms, repair open circuit in Pink wire between diagnostic connector and 60-pin connector. If resistance is not greater than 10 ohms, check resistance between Light Green wire terminal on diagnostic connector and pin No. 45 (Light Green wire) on 60-pin connector.
4. If resistance is greater than 10 ohms, repair open circuit in Light Green wire between diagnostic connector and 60-pin connector. If resistance is not greater than 10 ohms, ensure DRB-II and adapter cable are okay.
5. If all above are okay and a no-start condition exists, proceed to appropriate no-start test NS-12A. Checking System Power, Engine Controller, MAP Sensor

RAM TEST FAILURE

If message is displayed, replace DRB-II and proceed with diagnostics.

EMR LIGHT RESET PROCEDURE

1. The EMR light serves as the vehicle emissions control system service reminder. EMR light is not an emissions warning system; it is only a reminder to perform emissions servicing.
2. The EMR light will illuminate at 60,000, 82,500 and 120,000-mile intervals. Service specified components at designated interval. See «EMR LIGHT COMPONENT SERVICE INTERVAL»(/dodge/dakota/i-1987-1996/remont/testing-diagnostics/#engine-controls-tests-wcodes-25l) table. EMR LIGHT COMPONENT SERVICE INTERVAL Interval Component To Be Serviced 60,000 Miles Replace EGR Valve & Tube (If Equipped) Clean EGR Passage, Replace PCV Valve 82,500 Miles Replace Oxygen Sensor 120,000 Miles Replace EGR Valve & Tube (If Equipped) Clean EGR Passage, Replace PCV Valve
3. Once components have been serviced, EMR light can be reset. It will be necessary to place DRB-II in the FUEL/IGN MENU to reset EMR light. This menu is obtained when retrieving fault codes. See DRB-II METHOD under «RETRIEVING FAULT CODES»(/dodge/dakota/i-1987-1996/remont/testing-diagnostics/#engine-controls-tests-wcodes-25l__retrieving-fault-codes) under SELF-DIAGNOSTIC SYSTEM.
4. Once in FUEL/IGN MENU, press the down arrow to select No. 5) ADJUSTMENTS. Display will read as follows: ADJUSTMENTS, 1) ERASE FAULTS, 2) RESET MEMORY, 3) RESET EMR LIGHT, and 4) EMR MEMORY CHECK. Press the down arrow to select No. 3) RESET EMR LIGHT.
5. Display will ask if you are sure you want to reset EMR light. Press ENTER button to reset EMR light.

EMR MILEAGE TRANSFER

1. When SBEC is replaced, vehicle mileage from odometer must be copied to the replacement SBEC memory. Transfer of vehicle mileage will enable replacement SBEC to operate EMR light properly.
2. It will be necessary to place DRB-II in the FUEL/IGN MENU to reset EMR light. This menu is obtained when retrieving fault codes. See DRB-II METHOD under «RETRIEVING FAULT CODES»(/dodge/dakota/i-1987-1996/remont/testing-diagnostics/#engine-controls-tests-wcodes-25l__retrieving-fault-codes) under SELF-DIAGNOSTIC SYSTEM.
3. Once in FUEL/IGN MENU, press the down arrow to select No. 5) ADJUSTMENTS. Display will read as follows: ADJUSTMENTS, 1) ERASE FAULTS, 2) RESET MEMORY, 3) RESET EMR LIGHT, and 4) EMR MEMORY CHECK. Press the down arrow to select No. 4) EMR MEMORY CHECK.
4. Display will ask if you are sure you want to check EMR memory. Press ENTER button to continue. Display will read as follows: EMR MEMORY TEST, and WRITE TEST [------]. Display will now ask if instrument panel mileage is between a specified amount.
5. Press YES or NO button. If YES button is pressed, EMR memory check is completed. If NO button is pressed, enter mileage shown on the odometer. Press ENTER button to complete mileage transfer.

SBEC LOCATION

SBEC LOCATIONS

SUMMARY

If no hard fault codes (or only pass codes) are present, driveability symptoms exist, or intermittent codes exist, proceed to TESTS W/O CODES article for diagnosis by symptom (i.e. ROUGH IDLE, NO START, etc.), or intermittent diagnostic procedures.

Scheme 12

Note. Fault code charts may contain references to body types not covered in this article.

FAULT CODES

FAULT CODES (1)

TROUBLE SHOOTING CHARTS

Note. The following trouble shooting charts and illustrations are courtesy of Chrysler Motors.

NO START DIAGNOSTIC FLOW CHARTS: NS-1A TO NS-17A

Note. The following trouble shooting charts and illustrations are courtesy of Chrysler Motors.

Test NS-1A: Ignition Spark & Power Feed To Coil Ckt Diag. Scheme 13

Test NS-1A: (1 of 3) Ignition Spark & Power Feed To Coil. Scheme 14

Test NS-1A: (2 of 3) Ignition Spark & Power Feed To Coil. Scheme 15

Test NS-1A: (3 of 3) Ignition Spark & Power Feed To Coil. Scheme 16

Test NS-2A: (1 of 2) Fuel Spray & Fault Messages With DRB-II. Scheme 17

Test NS-2A: (2 of 2) Fuel Spray & Fault Messages With DRB-II. Scheme 18

Test NS-3A Ckt Diag: Injector Faults, Power To SBEC, MAP Sensor & Theft status. Scheme 19

Test NS-3A: (1 of 3) Injector Faults, Power To SBEC, MAP Sensor & Theft status. Scheme 20

Test NS-3A: (2 of 3) Injector Faults, Power To SBEC, MAP Sensor & Theft status. Scheme 21

Test NS-3A: (3 of 3) Injector Faults, Power To SBEC, MAP Sensor & Theft status. Scheme 22

NS-4A: CHECKING FOR FUEL PRESSURE, TPS & POWER FEED TO INJECTORS

Shadow and Sundance Convertible models are manufactured with either early or late design fuel, ignition and emission systems. Late design vehicles use an epoxy ignition coil, mounted on thermostat housing, and a high pressure fuel system requiring quick-connect fuel fittings. Early design vehicles use an oil-filled ignition coil, mounted on right inner fender, and a low pressure fuel system using hoses and clamps.

Test NS-4A: (1 of 2) Fuel Pressure, TPS & Power Feed To Injectors. Scheme 23

Test NS-4A: (2 of 2) Fuel Pressure, TPS & Power Feed To Injectors. Scheme 24

Test NS-5A Ckt Diag: Wet Plugs, MAP Sensor/Ignition Timing. Scheme 25

Test NS-5A: (1 of 2): Wet Plugs, MAP Sensor/Ignition Timing. Scheme 26

Test NS-5A: (2 of 2): Wet Plugs, MAP Sensor/Ignition Timing. Scheme 27

Test NS-5B: Valve Gear. Scheme 28

Test NS-6A: (1 of 2) Fuel Filter, Fuel Pump, Pressure Regulator & Power To Fuel Pump. Scheme 29

Test NS-6A: (2 of 2) Fuel Filter, Fuel Pump, Pressure Regulator & Power To Fuel Pump. Scheme 30

Test NS-6B: Fuel Filter, Fuel Pump, Pressure Regulator & Power To Fuel Pump. Scheme 31

Test NS-7A Ckt Diag: Flooding Fuel Injector. Scheme 32

Test NS-7A: (1 of 3) Flooding Fuel Injector. Scheme 33

Test NS-7A: (2 of 3) Flooding Fuel Injector. Scheme 34

Test NS-7A: (3 of 3) Flooding Fuel Injector. Scheme 35

Test NS-7B: (1 of 2) Flooding Fuel Injector. Scheme 36

Test NS-7B: (2 of 2) Flooding Fuel Injector. Scheme 37

Test NS-8A: (1 of 2) High Fuel Pressure At Psi. Regulator. Scheme 38

Test NS-8A: (2 of 2) High Fuel Pressure At Psi. Regulator. Scheme 39

Test NS-9A: (1 of 2) Defective Coil or Control Circuitry. Scheme 40

Test NS-9A: (2 of 2) Defective Coil or Control Circuitry. Scheme 41

Test NS-10A: (1 of 2) Injector, Control Circuit & SBEC. Scheme 42

Test NS-10A: (2 of 2) Injector, Control Circuit & SBEC. Scheme 43

Test NS-10B: (1 of 2) Injector, Control Circuit & SBEC. Scheme 44

Test NS-10B: (2 of 2) Injector, Control Circuit & SBEC. Scheme 45

Test NS-11A: DRB-II & System Faults. Scheme 46

Test NS-12A: Ckt Diag. System Power, MAP Sensor & SBEC. Scheme 47

Test NS-12A: (1 of 2) System Power, MAP Sensor & SBEC. Scheme 48

Test NS-12A: (2 of 2) System Power, MAP Sensor & SBEC. Scheme 49

Test NS-12B: Ckt Diag. System Power, MAP Sensor & SBEC. Scheme 50

Test NS-12B: (1 of 2) System Power, MAP Sensor & SBEC. Scheme 51

Test NS-12B: (2 of 2) System Power, MAP Sensor & SBEC. Scheme 52

Test NS-13A: Ckt Diag. Code 11, No Ignition Reference Signal During Cranking. Scheme 53

Test NS-13A: (1 of 3) Code 11, No Ignition Reference Signal During Cranking. Scheme 54

Test NS-13A: (2 of 3) Code 11, No Ignition Reference Signal During Cranking. Scheme 55

Test NS-13A: (3 of 3) Code 11, No Ignition Reference Signal During Cranking. Scheme 56

Test NS-13B: (1 of 2) Code 11, No Ignition Reference Signal During Cranking. Scheme 57

Test NS-13B: (2 of 2) Code 11, No Ignition Reference Signal During Cranking. Scheme 58

Test NS-13C: Code 11, No Ignition Reference Signal During Cranking. Scheme 59

Test NS-14A: (1 of 2) ASD Relay Circuit. Scheme 60

Test NS-14A: (2 of 2) ASD Relay Circuit. Scheme 61

Test NS-15A: (1 of 3) Checking ASD Relay Power Feed To Fuel Pump O2 Sensor & Injector. Scheme 62

Test NS-15A: (2 of 3) Checking ASD Relay Power Feed To Fuel Pump O2 Sensor & Injector. Scheme 63

Test NS-15A: (3 of 3) Checking ASD Relay Power Feed To Fuel Pump O2 Sensor & Injector. Scheme 64

Test NS-16A: Ckt Diag. Idle Speed Motor Operation. Scheme 65

Test NS-16A: Idle Speed Motor Operation. Scheme 66

Test NS-16B: Idle Speed Motor Operation. Scheme 67

Test NS-16C: Idle Speed Motor Operation. Scheme 68

Test NS-16D: Idle Speed Motor Operation. Scheme 69

Test NS-16E: Idle Speed Motor Operation. Scheme 70

NS-17A: PERFORMING NO FAULT CODE MECHANICAL TEST

At this point in the start-and-stall test procedure, if it is determined that all engine control systems are operating as designed and are not the cause of a no start-and-stall problem, the following additional items should be checked as possible causes

1. Check if any TECHNICAL SERVICE BULLETINS (TSBs) apply to vehicle.
2. Check engine vacuum.
3. Check engine compression.
4. Check for exhaust system restriction.
5. Check camshaft and crankshaft sprockets.
6. Check valve timing.
7. Check torque converter stall speed.
8. Check secondary ignition circuit for abnormal scope pattern.
9. Check for fuel contamination.
10. Ensure PCV system is functioning properly.

DRIVEABILITY DIAGNOSTIC FLOW CHARTS DR-1A TO DR-45A

Note. The following trouble shooting charts and illustrations are courtesy of Chrysler Motors.

DR-1A: CHECKING SYSTEM FOR FAULTS

Note. Battery must be fully charged and at rated capacity before performing any driveability test procedure. If vehicle starts and stalls repeatedly, perform test NS-3A: CHECKING FOR INJECTOR FAULTS, POWER TO ENGINE CONTROLLER, MAP SENSOR & THEFT ALARM STATUS.

1. Connect DRB-II to engine diagnostic connector. Read fault messages. If DRB-II displays fault messages, go to DR-1B: DRB-II FAULT MESSAGES. Go to step 9) if DRB-II displays ENGINE COLD TOO LONG. If DRB-II displays INTERNAL CONTROLLER FAILURE, go to step 8). If DRB-II displays NO FAULTS, go to next step.
2. If NO FAULTS message appears on DRB-II display, start engine. Allow engine to reach normal operating temperature. Set engine speed manually ( DO NOT use DRB-II to set speed) to 2000 RPM for about 10 seconds. Return engine to idle.
3. If vehicle is not equipped with A/C, go to step 5). If vehicle is equipped with A/C, put A/C fan on low speed. Turn A/C on. If engine stalls when A/C is turned on, turn ignition switch off.
4. Disconnect engine controller connector. Inspect engine controller connector for corroded or loose terminals. Repair as required. Turn ignition switch on. Put DRB-II in voltmeter mode.
5. Probe engine controller connector DB (Dark/Blue) wire at cavity No. 9. If voltage is less than 10 volts, repair DB wire. If voltage is more than 10 volts, replace engine controller. Perform test VER-2: VERIFICATION PROCEDURE 2.
6. If vehicle is equipped with A/T, apply brakes and shift through all gears. Return shift lever to Park. Read fault messages displayed on DRB-II.
7. If DRB-II still shows NO FAULTS, check TECHNICAL SERVICE BULLETINS for any pertinent information relating to driveability problems. If a TSB exists, perform corrective action. If driveability problem continues after performing TSB procedure or if no TSB information is found, perform test DR-30A: CHECKING SECONDARY IGNITION & TIMING.
8. If INTERNAL CONTROLLER FAILURE message appears on DRB-II display, replace engine controller. Perform test VER-2: VERIFICATION PROCEDURE 2.
9. If ENGINE COLD TOO LONG message appears on DRB-II display, check engine cooling system. Repair as required. Perform test VER-3: VERIFICATION PROCEDURE 3.

DR-1B: DRB-II FAULT MESSAGES

Using the DRB-II FAULT MESSAGES table, select the fault message and corresponding test. Correct all hard fault messages before proceeding to intermittent fault message.

DRB-II FAULT MESSAGES

Test DR-2A, Code 13: (1 of 2) Slow Change In Idle MAP Signal. Scheme 71

Test DR-2A, Code 13: (2 of 2) Slow Change In Idle MAP Signal. Scheme 72

Test DR-3A, Code 13, No Change In MAP From Start To Run. Scheme 73

Test DR-4A, Code 14: MAP Voltage Too Low. Scheme 74

Test DR-5A, Code 14: (1 of 2) MAP Voltage Too High. Scheme 75

Test DR-5A, Code 14: (2 of 2) MAP Voltage Too High. Scheme 76

Test DR-6A, Ckt Diag. Code 15, No Vehicle Speed Signal. Scheme 77

Test DR-6A, Code 15: (1 of 3) No Vehicle Speed Signal. Scheme 78

Test DR-6A, Code 15: (2 of 3) No Vehicle Speed Signal. Scheme 79

Test DR-6A, Code 15: (3 of 3) No Vehicle Speed Signal. Scheme 80

Test DR-7A, Ckt Diag. Code 21, O2 Signal Stays At Center. Scheme 81

Test DR-7A, Code 21: (1 of 2) O2 Signal Stays At Center. Scheme 82

Test DR-7A, Code 21: (2 of 2) O2 Signal Stays At Center. Scheme 83

Test DR-8A, Code 21: (1 of 2) O2 Signal Shorted To Voltage. Scheme 84

Test DR-8A, Code 21: (2 of 2) O2 Signal Shorted To Voltage. Scheme 85

Test DR-9A, Ckt Diag. Code 22, Coolant Sensor Voltage High. Scheme 86

Test DR-9A, Code 22: (1 of 2) Coolant Sensor Voltage High. Scheme 87

Test DR-9A, Code 22: (2 of 2) Coolant Sensor Voltage High. Scheme 88

Test DR-10A, Code 22: Coolant Sensor Voltage Low. Scheme 89

Test DR-11A, Code 23: Ckt Diag. Throttle Body Temp High. Scheme 90

Test DR-11A, Code 23: (1 of 2) Throttle Body Temp High. Scheme 91

Test DR-11A, Code 23: (2 of 2) Throttle Body Temp High. Scheme 92

Test DR-12A, Code 23: Throttle Body Temp Low. Scheme 93

Test DR-13A, Code 24: Ckt Diag. TPS Voltage High. Scheme 94

Test DR-13A, Code 24: (1 of 2) TPS Voltage High. Scheme 95

Test DR-13A, Code 24: (2 of 2) TPS Voltage High. Scheme 96

Test DR-14A, Code 24: TPS Voltage Low. Scheme 97

Test DR-15A, Code 25: (1 of 4) AIS Motor Circuits. Scheme 98

Test DR-15A, Code 25: (2 of 4) AIS Motor Circuits. Scheme 99

Test DR-15A, Code 25: (3 of 4) AIS Motor Circuits. Scheme 100

Test DR-15A, Code 25: (4 of 4) AIS Motor Circuits. Scheme 101

Test DR-16A, Code 31: Ckt Diag. Purge Solenoid Circuit. Scheme 102

Test DR-16A, Code 31: (1 of 3) Purge Solenoid Circuit. Scheme 103

Test DR-16A, Code 31: (2 of 3) Purge Solenoid Circuit. Scheme 104

Test DR-16A, Code 31: (3 of 3) Purge Solenoid Circuit. Scheme 105

Test DR-17A, Code 32: Ckt Diag. EGR Solenoid Circuit. Scheme 106

Test DR-17A, Code 32: (1 of 3) EGR Solenoid Circuit. Scheme 107

Test DR-17A, Code 32: (2 of 3) EGR Solenoid Circuit. Scheme 108

Test DR-17A, Code 32: (3 of 3) EGR Solenoid Circuit. Scheme 109

Test DR-18A, Code 32: (1 of 5) EGR System Failure. Scheme 110

Test DR-18A, Code 32: (2 of 5) EGR System Failure. Scheme 111

Test DR-18A, Code 32: (3 of 5) EGR System Failure. Scheme 112

Test DR-18A, Code 32: (4 of 5) EGR System Failure. Scheme 113

Test DR-18A, Code 32: (5 of 5) EGR System Failure. Scheme 114

Test DR-18B, Code 32: (1 of 5) EGR System Failure. Scheme 115

Test DR-18B, Code 32: (2 of 5) EGR System Failure. Scheme 116

Test DR-18B, Code 32: (3 of 5) EGR System Failure. Scheme 117

Test DR-18B, Code 32: (4 of 5) EGR System Failure. Scheme 118

Test DR-18B, Code 32: (5 of 5) EGR System Failure. Scheme 119

Test DR-18C, Code 32: EGR System Failure. Scheme 120

Test DR-19A, Code 33: (1 of 4) A/C Clutch Relay Circuit. Scheme 121

Test DR-19A, Code 33: (2 of 4) A/C Clutch Relay Circuit. Scheme 122

Test DR-19A, Code 33: (3 of 4) A/C Clutch Relay Circuit. Scheme 123

Test DR-19A, Code 33: (4 of 4) A/C Clutch Relay Circuit. Scheme 124

Test DR-20A, Code 33: (1 of 2) A/C Clutch Relay Circuit. Scheme 125

Test DR-20A, Code 33: (2 of 2) A/C Clutch Relay Circuit. Scheme 126

Test DR-21A, Code 33: (1 of 2) A/C Clutch Relay Circuit. Scheme 127

Test DR-21A, Code 33: (2 of 2) A/C Clutch Relay Circuit. Scheme 128

Test DR-22A, Code 33: (1 of 2) A/C Clutch Relay Circuit. Scheme 129

Test DR-22A, Code 33: (2 of 2) A/C Clutch Relay Circuit. Scheme 130

Test DR-23A, Code 33: (1 of 3) A/C Clutch Relay Circuit. Scheme 131

Test DR-23A, Code 33: (2 of 3) A/C Clutch Relay Circuit. Scheme 132

Test DR-23A, Code 33: (3 of 3) A/C Clutch Relay Circuit. Scheme 133

Test DR-24A, Code 35: Ckt Diag. Radiator Fan Relay Circuit. Scheme 134

Test DR-24A, Code 35: (1 of 4) Radiator Fan Relay Circuit. Scheme 135

Test DR-24A, Code 35: (2 of 4) Radiator Fan Relay Circuit. Scheme 136

Test DR-24A, Code 35: (3 of 4) Radiator Fan Relay Circuit. Scheme 137

Test DR-24A, Code 35: (4 of 4) Radiator Fan Relay Circuit. Scheme 138

Test DR-25A, Code 35: (1 of 2) Radiator Fan Relay Circuit. Scheme 139

Test DR-25A, Code 35: (2 of 2) Radiator Fan Relay Circuit. Scheme 140

Test DR-26A, Code 35: (1 of 2) Radiator Fan Relay Circuit. Scheme 141

Test DR-26A, Code 35: (2 of 2) Radiator Fan Relay Circuit. Scheme 142

Test DR-27A, Code 35: (1 of 2) Radiator Fan Relay Circuit. Scheme 143

Test DR-27A, Code 35: (2 of 2) Radiator Fan Relay Circuit. Scheme 144

Test DR-28A, Code 37: Ckt Diag. Torque Converter Lock-Up Solenoid. Scheme 145

Test DR-28A, Code 37: (1 of 3) Torque Converter Lock-Up Solenoid. Scheme 146

Test DR-28A, Code 37: (2 of 3) Torque Converter Lock-Up Solenoid. Scheme 147

Test DR-28A, Code 37: (3 of 3) Torque Converter Lock-Up Solenoid. Scheme 148

Test DR-29A, Code 63: (1 of 2) SBEC Failure EMR Mileage Not Stored & EEPROM Write Denied. Scheme 149

Test DR-29A, Code 63: (2 of 2) SBEC Failure EMR Mileage Not Stored & EEPROM Write Denied. Scheme 150

Test DR-30A: (1 of 2) Secondary Ignition & Timing. Scheme 151

Test DR-30A: (2 of 2) Secondary Ignition & Timing. Scheme 152

Test DR-31A: (1 of 2) Fuel Pressure. Scheme 153

Test DR-31A: (2 of 2) Fuel Pressure. Scheme 154

Test DR-31B: (1 of 2) Fuel Pressure. Scheme 155

Test DR-31B: (2 of 2) Fuel Pressure. Scheme 156

Test DR-32A: (1 of 2) Coolant & TPS Sensor Calibration. Scheme 157

Test DR-32A: (2 of 2) Coolant & TPS Sensor Calibration. Scheme 158

Test DR-33A: (1 of 2) MAP Sensor Calibration. Scheme 159

Test DR-33A: (2 of 2) MAP Sensor Calibration. Scheme 160

Test DR-34A: Oxygen Sensor Switching. Scheme 161

Test DR-34B: (1 of 2) Oxygen Sensor Switching. Scheme 162

Test DR-34B: (2 of 2) Oxygen Sensor Switching. Scheme 163

Test DR-35A: Ckt Diag. Idle Speed Motor Operation. Scheme 164

Test DR-35A: (1 of 2) Idle Speed Motor Operation. Scheme 165

Test DR-35A: (2 of 2) Idle Speed Motor Operation. Scheme 166

Test DR-35B: Idle Speed Motor Operation. Scheme 167

Test DR-35C: Idle Speed Motor Operation. Scheme 168

Test DR-35D: Idle Speed Motor Operation. Scheme 169

Test DR-35E: Idle Speed Motor Operation. Scheme 170

Test DR-36A: Ckt Diag. Park/Neutral Switch Operation. Scheme 171

Test DR-36A: (1 of 2) Park/Neutral Switch Operation. Scheme 172

Test DR-36A: (2 of 2) Park/Neutral Switch Operation. Scheme 173

Test DR-37A: Ckt Diag. SBEC Grounds & Power Circuits. Scheme 174

Test DR-37A: (1 of 2) SBEC Grounds & Power Circuits. Scheme 175

Test DR-37A: (2 of 2) SBEC Grounds & Power Circuits. Scheme 176

Test DR-38A: (1 of 2) EGR Operation Federal Emissions. Scheme 177

Test DR-38A: (2 of 2) EGR Operation Federal Emissions. Scheme 178

Test DR-38B: EGR Operation Federal Emissions. Scheme 179

Test DR-38C: (1 of 5) EGR Operation Federal Emissions. Scheme 180

Test DR-38C: (2 of 5) EGR Operation Federal Emissions. Scheme 181

Test DR-38C: (3 of 5) EGR Operation Federal Emissions. Scheme 182

Test DR-38C: (4 of 5) EGR Operation Federal Emissions. Scheme 183

Test DR-38C: (5 of 5) EGR Operation Federal Emissions. Scheme 184

Test DR-39A: Ckt Diag. Engine Vacuum. Scheme 185

Test DR-40A: (1 of 2) Engine Vacuum. Scheme 186

Test DR-40A: (2 of 2) Engine Vacuum. Scheme 187

DR-41A: PERFORMING NO FAULT CODE MECHANICAL TEST

At this point in the driveability test procedure, if it is determined that all engine control systems are operating as designed and are not the cause of driveability problem, check the following additional items for possible causes

1. Check valve timing.
2. Check torque converter stall speed.
3. Check engine compression.
4. Check camshaft and crankshaft sprockets.
5. Check for internal power brake booster vacuum leaks.
6. Check for fuel contamination.
7. Check for exhaust system restriction.
8. Ensure injectors are not plugged or restricted.
9. Ensure injector control wire is connected to correct injector.
10. Ensure engine vacuum is at least 13 in. Hg.
11. Ensure PCV system is functioning properly.

Test DR-42A: Intermittent Test For Solenoids & Relays. Scheme 188

Test DR-43A: Intermittent Voltage Sensor. Scheme 189

Test DR-43B: Intermittent Test For MAP Sensor Signal Change. Scheme 190

Test DR-44A: Intermittent Test For Idle Motor Circuits. Scheme 191

Test DR-45A: Intermittent Test For Injector Circuits. Scheme 192

VER-1: VERIFICATION PROCEDURE 1

1. Inspect vehicle to ensure all components are connected. Reassemble and reconnect components as necessary. Attempt to start engine. If engine does not start, return to test NS-1A: CHECKING FOR IGNITION SPARK & POWER FEED TO COIL.
2. If engine starts and engine controller has been changed, go to next step. If engine starts and engine controller has not been changed, connect DRB-II to engine diagnostic connector and erase faults. Repair is now complete.
3. If vehicle is equipped with factory theft alarm system, start engine about 20 times to activate theft alarm system. If vehicle is an AS or AN body, write EMR mileage into the new engine controller. Repair is now complete.

VER-2: VERIFICATION PROCEDURE 2

1. If test VER-3: VERIFICATION PROCEDURE 3 has been performed previously, perform test VER-3 again. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary.
2. If another fault exists that has not been corrected, return to DR-1B: DRB-II FAULT MESSAGES and follow path specified by other fault. If engine controller has been replaced and vehicle is equipped with factory theft alarm system, start engine about 20 times to activate theft alarm system. If vehicle is an AS or AN body, write EMR mileage into new engine controller.
3. Connect DRB-II to engine diagnostic connector and erase faults. Ensure no other faults are present. To ensure no other faults are present, start engine. Allow engine to reach normal operating temperature. Increase engine speed to 2000 RPM for about 10 seconds. Return engine to idle.
4. If vehicle is equipped with A/T, apply brakes and cycle through all transmission gear positions. Place gear selector in Park. If vehicle is equipped with A/C, turn A/C on. Set blower speed to LOW.
5. Turn engine off. Start engine. Allow engine to idle for about 2 minutes. Turn engine off. Using DRB-II, check for fault messages. If NO FAULT message appears on DRB-II display, test is complete.
6. If repaired fault resets or another fault sets, check TECHNICAL SERVICE BULLETINS for any pertinent information relating to problem. If a TSB exists, perform corrective action. If another fault sets, return to DR-1B: DRB-II FAULT MESSAGES.

VER-3: VERIFICATION PROCEDURE 3

1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If another fault is present that has not been corrected, return to DR-1B: DRB-II FAULT MESSAGES and follow path specified by other fault.
2. If engine controller has been changed and vehicle is equipped with factory theft alarm system, start engine about 20 times to activate theft alarm system. If vehicle is an AS or AN body, write EMR mileage into new engine controller.
3. Connect DRB-II to engine diagnostic connector. Erase fault messages. Disconnect DRB-II. Ensure no other fault messages are present. To ensure no other fault messages are present, start engine. If vehicle is equipped with A/C, turn A/C on. Set blower speed to LOW.
4. Drive vehicle for about 5 minutes. During this time, attain a speed above 40 MPH or more. Ensure transmission shifts through all gears. Upon completion of road test, turn engine off.
5. Start engine. Allow engine to idle for about 2 minutes. Turn engine off. Connect DRB-II to engine diagnostic connector. Using DRB-II, check for fault messages. If no fault messages are present, test is complete.
6. If repaired fault message resets or another fault message sets, check TECHNICAL SERVICE BULLETINS for any pertinent information relating to driveability problems. If a TSB exists, perform corrective action. If another fault sets, return to DR-1B: DRB-II FAULT MESSAGES.

See also:
• CLEARING FAULT CODES
• RETRIEVING FAULT CODES
• FAULT CODES