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Engine Controls - Basic Diagnostic Procedures Dodge Grand Caravan IV

Testing & Diagnostics 6 illustrations ~3606 words

INTRODUCTION

The following diagnostic steps will help prevent overlooking a simple problem. This is also where to begin diagnosis for a no-start condition.

The first step in diagnosing any driveability problem is verifying the customer's complaint with a test drive under the conditions the problem reportedly occurred.

Before entering self-diagnostics, perform a careful and complete visual inspection. Most engine control problems result from mechanical breakdowns, poor electrical connections or damaged/misrouted vacuum hoses. Before condemning the computerized system, perform each test listed in this article.

Note. Unless stated otherwise in test procedure, perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) having a minimum 10-megohm input impedance.

VISUAL INSPECTION

Most driveability problems in the engine control system result from faulty wiring, poor electrical connections or leaking air and vacuum hose connections. To avoid unnecessary component testing, perform a visual inspection before beginning self-diagnostic tests.

Visually inspect all electrical wiring, looking for chafed, stretched, cut or pinched wiring. Ensure electrical connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and are not cracked, pinched or cut. See VACUUM DIAGRAMS - TRUCKS article. Inspect air induction system for possible vacuum leaks.

Cylinder Compression Pressure

WARNINGDO NOT use ignition switch during compression tests on fuel injected vehicles. Use a remote starter to crank engine. Fuel injectors on many models are triggered by ignition switch during cranking mode, which can create a fire hazard or contaminate the engine's oiling system.

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.

ApplicationPsi (kg/cm 2 )
Normal Compression Pressure(1)
Minimum Compression Pressure100 (7)
Maximum Variation Between Cylinders(2)
(1) Information is not available from manufacturer. (2) Maximum variation is 25 percent.
(1)Information is not available from manufacturer.
(2)Maximum variation is 25 percent.

COMPRESSION SPECIFICATIONS

Scheme 73

Scheme 73
Scheme 73

Scheme 74

Scheme 74
Scheme 74

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»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures) table.
ConditionPossible CauseCorrection
Air Escapes Through Throttle BodyIntake Valve Bent, Burnt Or Not Seated ProperlyInspect Valve, Valve Seat & Valve Springs
Air Escapes Through TailpipeExhaust Valve Bent, Burnt Or Not Seated ProperlyInspect Valve, Valve Seat & Valve Springs
Air Escapes Through RadiatorHead Gasket Leaking, Cracked Cylinder Head Or BlockRemove Cylinder Head & Inspect
More Than 50 Percent Leakage From Adjacent CylindersHead Gasket Leaking Or Crack In Cylinder Head Or Block Between Adjacent CylindersRemove Cylinder Head & Inspect
More Than 25 Percent Leakage & Air Escapes Through Oil Filler Cap Opening OnlyStuck Or Broken Piston Rings, Cracked Piston, Worn Rings Or Cylinder WallsInspect For Broken Rings Or Piston, Measure Ring Gap & Cylinder Diameter, Taper & Out-Of-Round

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.

NO-START DIAGNOSIS

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 . If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING in REMOVAL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 to ensure system is functioning properly. See the following: On 2.4L, see POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY & VOYAGER - 3.3L & 3.8L article.

Possible Causes

  1. Fuel Pump Relay
  2. No Start Pre-Test
  3. Powertrain Fuses Open
  4. Fuel Pressure Out Of Specs
  5. Restricted Fuel Supply Line
  6. Fuel Pump Inlet Strainer Plugged
  7. Fuel Pump Module
  8. Fuel Pump Relay Fused B+ Circuit
  9. Other Possible Causes For No Start
  10. Fuel Pump Relay Output Circuit Open
  11. Fuel Pump Ground Circuit Open/High Resistance
  12. IPM Fuse & Relay Center

Testing

  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»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-system-component-testing__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 the following: On 2.4L, see «RETRIEVING DIAGNOSTIC TROUBLE CODES»(ref-157113-S09931213922003080500000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see «RETRIEVING DIAGNOSTIC TROUBLE CODES»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY & VOYAGER - 3.3L & 3.8L 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 - CARAVAN, TOWN & COUNTRY, & VOYAGER article in ACCESSORIES & EQUIPMENT. Using scan tool select CLEAR PCM (BATT DISCONNECT). Crank engine over several times. Using scan tool, check for DTCs. If no DTCs exist, go to next step. If any DTCs are present, perform appropriate diagnostic test. See the following: On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__diagnostic-trouble-code-definitions) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY & VOYAGER - 3.3L & 3.8L article.
  2. Turn ignition off. Check Integrated Power Module (IPM) for blown fuses. IPM is located on left side of engine compartment, next to battery. (Scheme 73)and (Scheme 74). 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»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures__fuel-system-pressure-release). 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»(/dodge/grand-caravan/iv-2000-2007/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) under FUEL SYSTEMS in REMOVAL & 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»(/dodge/grand-caravan/iv-2000-2007/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-pump-module) under FUEL SYSTEMS in REMOVAL & 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»(/dodge/grand-caravan/iv-2000-2007/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-pump-module) under FUEL SYSTEMS in REMOVAL & 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»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures).
  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 73)and (Scheme 74). 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 77) Measure resistance of Dark Blue/Orange wire between fuel pump module harness connector and terminal No. 2 at IPM C8 harness connector. (Scheme 78) 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 . If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING in appropriate SELF-DIAGNOSTICS article. After each repair procedure has been completed, reconnect all components. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 to ensure system is functioning properly. See the following: On 2.4L, see POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY & VOYAGER - 3.3L & 3.8L article.

  1. Turn ignition off. Disconnect PCM connectors. PCM is located on left side of engine compartment, near front of battery. (Scheme 73) 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 75) 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 Integrated Power Module (IPM) on left side of engine compartment, next to battery. (Scheme 73) Also inspect fuse No. 17 in IPM. (Scheme 74)
  2. Turn ignition on. Using a test light connected to ground, probe terminal No. 20 (Pink/Gray wire) at PCM C1 harness connector. (Scheme 76) 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 75

Scheme 75
Scheme 75

Scheme 76

Scheme 76
Scheme 76

FUEL SYSTEM PRESSURE RELEASE

WARNINGALWAYS release fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
  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 73)and (Scheme 74).
  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.
  1. Fuel Pump Relay
  2. Fuel Pressure Out Of Specs
  3. Restricted Fuel Supply Line
  4. Fuel Pump Inlet Strainer Plugged
  5. Fuel Pump Module
  6. Fuel Delivery System Operation
  7. Fuel Pump Relay Fused B+ Circuit
  8. Fuel Pump Relay Output Circuit Open
  9. Fuel Pump Ground Circuit Open/High Resistance
  1. Locate Integrated Power Module (IPM) on left side of engine compartment, next to battery. (Scheme 73) Inspect fuse No. 17 (20-amp) in IPM. (Scheme 74) 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»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures__fuel-system-pressure-release). 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»(/dodge/grand-caravan/iv-2000-2007/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) under FUEL SYSTEMS in REMOVAL & 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»(/dodge/grand-caravan/iv-2000-2007/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-pump-module) under FUEL SYSTEMS in REMOVAL & 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»(/dodge/grand-caravan/iv-2000-2007/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-pump-module) under FUEL SYSTEMS in REMOVAL & 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»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures).
  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 74) 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 77) Measure resistance of Dark Blue/Orange wire between fuel pump module harness connector and terminal No. 2 at IPM C8 harness connector. (Scheme 78) 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 77

Scheme 77
Scheme 77

Scheme 78

Scheme 78
Scheme 78

Fuel Pump Relay

Individual fuel pump relay testing is not available from manufacturer. For fuel pump relay circuit testing, perform fuel pump relay related diagnostic test. See the following

  1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article.
  2. On 3.3L and 3.8L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__diagnostic-trouble-code-definitions) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY & VOYAGER - 3.3L & 3.8L article.

IGNITION SYSTEMS

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

CAMSHAFT POSITION SENSOR

For camshaft position sensor testing, perform related diagnostic test. See

  1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article.
  2. On 3.3L and 3.8L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__diagnostic-trouble-code-definitions) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY & VOYAGER - 3.3L & 3.8L article.

CRANKSHAFT POSITION SENSOR

For crankshaft position sensor testing, perform related diagnostic test. See

  1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article.
  2. On 3.3L and 3.8L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__diagnostic-trouble-code-definitions) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY & VOYAGER - 3.3L & 3.8L 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.

IGNITION TIMING

Ignition timing is controlled by the powertrain control module and is not adjustable.

CARAVAN

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

GRAND CARAVAN

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

TOWN & COUNTRY

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

VOYAGER

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

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