Engine Controls - System & Component Testing Dodge Grand Caravan IV

INTRODUCTION

Before testing separate components or systems, follow proper workflow. See the following

1. On 2.4L, see «DIAGNOSTIC PROCEDURE»(ref-157113-S28006070752003080500000) DIAGNOSTIC PROCEDURE under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article.
2. On 3.3L and 3.8L, see «DIAGNOSTIC PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__diagnostic-procedure) DIAGNOSTIC PROCEDURE under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

On all models, if no Diagnostic Trouble Codes (DTC) are present and a no-start condition exists, proceed to NO-START DIAGNOSIS in BASIC DIAGNOSTIC PROCEDURES - CARAVAN, TOWN & COUNTRY & VOYAGER article. If no DTCs are present and a driveability condition exists, proceed to TROUBLE SHOOTING - NO CODES - CARAVAN, TOWN & COUNTRY & VOYAGER article for diagnosis by symptom (i.e., ROUGH IDLE, ENGINE STALLS, etc.).

Note. Testing individual components does not isolate short or open circuits. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate shorted or open wiring harness.

COMPUTERIZED ENGINE CONTROLS

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS . 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.

POWERTRAIN CONTROL MODULE

Possible Causes

1. PCM Fused B+ Circuit
2. PCM Fused Ignition Switch Output Circuit
3. PCM Ground Circuits

Checking Power & Ground Circuits

Test Procedure

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. PCM is located on left side of engine compartment, near front of battery. (Scheme 79) 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 80) 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 79) Also inspect fuse No. 17 in IPM. (Scheme 81)
2. Turn ignition on. Using a test light connected to ground, probe terminal No. 20 (Pink/Gray wire) at PCM C1 harness connector. (Scheme 82) 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. (Scheme 82) 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. Test is complete. 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 79

Scheme 80

Scheme 81

Scheme 82

A/C PRESSURE SENSOR

1. A/C pressure sensor may also be referred to as A/C pressure transducer. A/C pressure transducer is located on A/C refrigerant line between filter-drier and expansion valve in right rear corner of engine compartment. (Scheme 83)
2. Ensure work area around A/C pressure sensor is not less than 50°F (10°C) when testing A/C pressure sensor. Ensure electrical connector at A/C pressure sensor is clean and properly connected.
3. Apply parking brake. Ensure shift lever is in Park or Neutral. Start engine and allow engine to idle. Connect scan tool to Data Link Connector (DLC). DLC is located below driver's side of instrument panel. (Scheme 84)
4. For A/C system operation, a voltage between.451 volt (low-pressure cutout) to 4.519 volts (high-pressure cutout) is required. Using displayed voltage, determine if A/C pressure sensor operates correctly. See «A/C PRESSURE SENSOR SPECIFICATIONS»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-system-component-testing) table. Replace A/C pressure sensor if defective.

A/C PRESSURE SENSOR SPECIFICATIONS

Scheme 83

Scheme 84

BRAKE SWITCH

Note. Brake switch may also be referred to as brakelight switch.

1. Brake switch is located near top of brake pedal. Disconnect brake switch connector. It may be necessary to remove brake switch for access to electrical connector. If necessary to remove brake switch, see «BRAKE SWITCH»(/dodge/grand-caravan/iv-2000-2007/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__brake-switch) under SENSORS & SWITCHES in REMOVAL & INSTALLATION - CARAVAN, TOWN & COUNTRY, & VOYAGER article.
2. With brake switch in released position (plunger extended), check continuity between brake switch terminals. (Scheme 85) Continuity should exist between terminals No. 1 and 2. Continuity should not exist between terminals No. 3 and 4, or terminals No. 5 and 6. If continuity is not as specified, replace brake switch.
3. With brake switch in depressed position (plunger pushed in), check continuity between brake switch terminals. Continuity should exist between terminals No. 3 and 4, and terminals No. 5 and 6. Continuity should not exist between terminals No. 1 and 2. If continuity is not as specified, replace brake switch.

Scheme 85

CAMSHAFT POSITION SENSOR

On 2.4L, Camshaft Position (CMP) sensor is located on rear of cylinder head, just below valve cover. On 3.3L and 3.8L, CMP sensor is located on top of timing chain cover, just below thermostat housing. On all models, individual component testing is not available from manufacturer. If camshaft position sensor or wiring circuit failure exists, a DTC may be stored in the powertrain control module. See the following

1. On 2.4L, see «DTC P0340: CAMSHAFT POSITION SENSOR CIRCUIT»(ref-157113-S21133583292003080500000) under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article.
2. On 3.3L and 3.8L, see «DTC P0340: NO CAM SIGNAL AT PCM»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__dtc-p0340-no-cam-signal-at) under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

CRANKSHAFT POSITION SENSOR

On 2.4L, Crankshaft Position (CKP) sensor is located on cylinder block, near oil filter. On 3.3L and 3.8L, CKP sensor is located on top of transaxle housing, above flywheel. On all models, individual component testing is not available from manufacturer. If CKP sensor or wiring circuit failure exists, a DTC may be stored in powertrain control module. See the following

1. On 2.4L, see «DTC P0335: CRANKSHAFT POSITION SENSOR CIRCUIT»(ref-157113-S37609315622003080500000) under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 2.4L article.
2. On 3.3L and 3.8L, see «DTC P0320: NO CRANK REFERENCE SIGNAL AT PCM»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__dtc-p0320-no-crank-reference-signal) under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

ENGINE COOLANT TEMPERATURE SENSOR

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 to ensure system is functioning properly. On 2.4L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

Note. The following procedure assumes that the cooling system thermostat is functioning properly. Test works best if performed on a totally cold engine (cold soak).

1. Turn ignition on. Using scan tool, read Engine Coolant Temperature (ECT) sensor value. If engine coolant temperature is more than 180°F (82°C), allow engine coolant temperature to cool down to 150°F (66°C) before proceeding. If engine coolant temperature is 150°F (66°C) or less, start engine and monitor scan tool until engine coolant temperature reaches 180°F (82°C).
2. If ECT sensor value increases smoothly, go to next step. If ECT sensor value increase is erratic, check for cooling system problems and repair as necessary. If cooling system is okay, replace ECT sensor. ECT sensor is located on thermostat housing (2.4L) or is threaded into a coolant passage near thermostat housing (3.3L and 3.8L). (Scheme 86)or (Scheme 87).
3. If coolant temperature reaches 180°F (82°C) or more, no problem is indicated at this time. Test is complete. If coolant temperature does not reach 180°F (82°C) or more, check for cooling system problems and repair as necessary. If cooling system is okay, replace ECT sensor.

Scheme 86

Scheme 87

HEATED OXYGEN SENSOR

Individual component testing is not available from manufacturer. If heated oxygen sensor or wiring circuit failure exists, a DTC may be stored in powertrain control module. Perform appropriate HO2S DTC test. See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

INLET AIR TEMPERATURE SENSOR

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 to ensure system is functioning properly. See the following: On 2.4L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

Note. When performing this test, DO NOT allow more than 5 minutes between measuring temperature of Inlet Air Temperature (IAT) sensor with scan tool and measuring the air temperature inside of intake manifold with temperature probe.

Turn ignition on. Using scan tool, read and record IAT sensor value. Remove IAT sensor. IAT sensor is located on side of throttle body and has a Black 2-pin connector with Dark Blue/Light Green and Dark Blue/Dark Green wires. (Scheme 88)and (Scheme 89). Using a thermometer, read temperature inside IAT sensor opening. If IAT sensor value is within 10 degrees of thermometer reading, reinstall IAT sensor. IAT sensor is operating properly. Test is complete. If IAT sensor value is not within 10 degrees of thermometer reading, replace IAT sensor.

Scheme 88

Scheme 89

KNOCK SENSOR

Note. On the 3.3L and 3.8L, knock sensor testing is not available from manufacturer. Only a location is given.

On 2.4L, knock sensor is located on side of cylinder block, in front of starter. On 3.3L and 3.8L, knock sensor is located on side of cylinder block. On all models, knock sensor has a 2-pin connector with Dark Blue/Yellow and Dark Blue/Dark Green wires. Individual component testing is not available from manufacturer. If knock sensor or wiring circuit failure exists, a DTC may be stored in powertrain control module. On 2.4L, see DTC P0325: KNOCK SENSOR #1 CIRCUIT under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article.

LEAK DETECTION PUMP SWITCH (3.3L & 3.8L)

For leak detection pump switch testing, see DTC P1494: LEAK DETECTION PUMP SW OR MECHANICAL under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

MANIFOLD ABSOLUTE PRESSURE SENSOR

Individual component testing is not available from manufacturer. Perform related diagnostic test. See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

PARK/NEUTRAL SWITCH (3-SPEED A/T)

See PARK/NEUTRAL POSITION SWITCH (3-SPEED A/T) under MISCELLANEOUS CONTROLS.

THROTTLE POSITION SENSOR

Individual component testing is not available from manufacturer. Perform related diagnostic test. See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

VEHICLE SPEED SENSOR

Individual component testing information is not available from manufacturer. If VSS or wiring circuit failure exists, a DTC may be stored in PCM. Perform related diagnostic test. See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

A/C CLUTCH RELAY

See A/C CLUTCH RELAY OUTPUT under MISCELLANEOUS CONTROLS.

AUTO SHUTDOWN RELAY

See AUTO SHUTDOWN RELAY under MISCELLANEOUS CONTROLS.

EVAP PURGE SOLENOID

Turn ignition off. Disconnect EVAP purge solenoid connector located on lower right side of engine compartment, near radiator. (Scheme 90) Measure resistance between EVAP purge solenoid terminals. If resistance is 10-15 ohms, EVAP purge solenoid is okay. If resistance is not 10-15 ohms, replace EVAP purge solenoid. If EVAP purge solenoid or wiring circuit failure exists, a DTC may be stored in PCM. See the following

1. On 2.4L, see «DTC P0443: EVAP PURGE SOLENOID CIRCUIT»(ref-157113-S16518843982003080500000) under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article.
2. On 3.3L and 3.8L, see «DTC P0443: EVAP PURGE SOLENOID CIRCUIT»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-tests-wcodes-33l-38l__dtc-p0443-evap-purge-solenoid-circuit) under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 3.3L & 3.8L article.

Scheme 90

IDLE AIR CONTROL MOTOR

Individual component testing is not available from manufacturer. Perform related diagnostic test. See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

RADIATOR FAN RELAY

See RADIATOR FAN RELAY OUTPUT under MISCELLANEOUS CONTROLS.

STARTER RELAY

See STARTER RELAY under MISCELLANEOUS CONTROLS.

FUEL SYSTEM PRESSURE RELEASE

1. Remove fuel filler cap. Remove fuel pump relay from Integrated Power Module (IPM). IPM is located on left side of engine compartment, next to battery. (Scheme 79)and (Scheme 81).
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. Using scan tool, erase any DTCs that may have set after fuel pressure release procedure.

FUEL PRESSURE

To check fuel pressure, see CHECKING FUEL DELIVERY under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - CARAVAN, TOWN & COUNTRY, & VOYAGER article.

See AUTO SHUTDOWN RELAY under MISCELLANEOUS CONTROLS.

Fuel Injector

Disconnect fuel injector connector. Measure resistance between fuel injector terminals. Resistance should be 10-16 ohms at 68°F (20°C). If resistance is not as specified, replace fuel injector.

Fuel Pressure Regulator

Fuel pressure regulator is a nonadjustable in-tank pressure regulator mounted on fuel pump module in top of fuel tank. Individual component testing is not available from manufacturer. To test pressure regulator, check fuel pressure. See CHECKING FUEL DELIVERY under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - CARAVAN, TOWN & COUNTRY, & VOYAGER article.

HIGH TENSION WIRE RESISTANCE

HIGH TENSION WIRE RESISTANCE

IGNITION COIL

Individual component testing is not available from manufacturer. For ignition coil control circuit testing, perform related diagnostic test. See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

EVAP Canisters

All models are equipped with 2 EVAP canisters. EVAP canisters are located on frame rail, directly below the driver's seat. (Scheme 91) Check EVAP canisters for loose, missing, cracked or broken connections and parts. Repair or replace as necessary. No liquid should be in canister.

Scheme 91

Fuel Tank Rollover Valves

All models are equipped with 2 rollover valves located on top of fuel tank, at each corner of fuel tank. Any sign of fuel in EVAP canisters may indicate a defective rollover valve. EVAP canisters are located on frame rail, directly below the driver's seat. (Scheme 91) Rollover valves are not serviceable. If rollover valve is defective, fuel tank must be replaced. Replace EVAP canisters and/or fuel tank as necessary.

PCV Valve

1. With engine idling, remove the hose from the PCV valve. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. A strong vacuum should also be felt when a finger is placed over the valve inlet.
2. Install hose on PCV valve. Remove the make-up air hose from the air plenum at the rear of the engine. Hold a piece of stiff paper loosely over the end of the make-up air hose.
3. After allowing approximately one minute for crankcase pressure to reduce, the paper should draw up against the hose with noticeable force. If the engine does not draw the paper against the grommet after installing a new valve, replace the PCV valve.
4. Turn the engine off. Remove the PCV valve from intake manifold. The valve should rattle when shaken.
5. Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. If the valve rattles, apply a light coating of Loctite Pipe Sealant With Teflon to the threads. Thread the PCV valve into the manifold plenum and tighten to 60 INCH lbs. (7 N.m).

DRIVEABILITY PROBLEMS

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

START & STALL CONDITION

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS . If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING. After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 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. Checking DTCs
2. Checking SKIM DTCs
3. Fuel Pressure Out Of Specs
4. TP Sensor Sweep
5. TP Sensor Voltage Greater Than 0.92 Volt With Throttle Closed
6. ECT Sensor Operation
7. Other Possible Causes For Start & Stall
8. Restricted Fuel Supply Line
9. Fuel Pump Inlet Strainer Plugged
10. Fuel Pump Module

1. Turn ignition on. Using scan tool, check for Diagnostic Trouble Codes (DTC). If no DTCs are present, go to next step. If any DTCs are present, perform appropriate diagnostic test. See the following: On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.
2. Using scan tool, read and record Sentry Key Immobilizer Module (SKIM) DTC (fault) messages. If no SKIM DTC messages are present, go to next step. If any SKIM DTC messages are present, a fault exists in anti-theft system. Perform appropriate test. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
3. Turn ignition off. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/dodge/grand-caravan/iv-2000-2007/remont/testing-diagnostics/#engine-controls-system-component-testing__fuel-system-pressure-release) under FUEL SYSTEMS. Connect a fuel pressure gauge to test port on fuel rail. Using scan tool, actuate ASD fuel system test. Allow fuel pressure gauge to stabilize. Stop ASD fuel system activation. Fuel pressure should be 53-63 psi (365-434 kPa). If fuel pressure is less than specified, go to next step. If fuel pressure is more than specified, replace fuel pressure regulator. See «FUEL PRESSURE REGULATOR»(/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 6 .
4. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel pump module at fuel tank. Connect Fuel Line Adapter (6539) between disconnected fuel line and fuel pump module. Connect fuel pressure gauge to fuel line adapter hose. Turn ignition on. Using scan tool, actuate ASD fuel system test and note fuel pressure. Fuel pressure should be 53-63 psi (365-434 kPa). If fuel pressure is as specified, stop ASD fuel system activation. Release fuel pressure, and repair or replace fuel supply line. If fuel pressure is not as specified, stop ASD fuel system activation and go to next step.
5. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. See «FUEL PUMP MODULE»(/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.
6. Turn ignition off. Release fuel pressure. Disconnect fuel supply line from fuel rail. Install Fuel Line Pressure Test Adapter Hose (6539 for 5/16" fuel lines or 6631 for 3/8" fuel lines) between disconnected fuel line and fuel rail. Remove fuel fill cap. Insert other end of hose into a graduated container suitable for gasoline.
7. Using scan tool, actuate ASD fuel system test for 7 seconds. If fuel volume is .5 pt. (.25L) or more, go to next step. If fuel volume is less than .5 pt. (.25L), check for a kinked fuel line between fuel pump module and fuel rail. Repair fuel lines as necessary and retest. If fuel line is okay, replace fuel pump module. See «FUEL PUMP MODULE»(/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 on. Using scan tool, monitor TP sensor voltage while slowly depressing throttle pedal from idle position to wide open throttle position. If voltage changes smoothly, go to next step. If voltage does not change smoothly, replace TP sensor.
9. Ensure throttle is fully closed and against throttle stop. Using scan tool, read TP sensor voltage. If voltage is .92 volt or less, go to next step. If voltage is more than .92 volt, check for binding throttle linkage. Repair linkage as necessary. If linkage is not binding, replace TP sensor.
10. Turn ignition on. Using scan tool, read Engine Coolant Temperature (ECT) sensor value. If engine coolant temperature is more than 180°F (82°C), allow engine coolant temperature to cool down to 150°F (66°C) before proceeding. If engine coolant temperature is 150°F (66°C) or less, start engine and monitor scan tool until engine coolant temperature reaches 180°F (82°C). If ECT sensor value increases smoothly, go to next step. If ECT sensor value increase is erratic, check for cooling system problems and repair as necessary. If cooling system is okay, replace ECT sensor.
11. Check the following additional items as possible causes for start and stall condition: Check for any technical service bulletins that may apply. Fuel must be free of contamination. Engine exhaust system must be free of restrictions. Engine compression must be within specification. Engine valve timing must be within specification. Engine vacuum must be at least 13 in. Hg with shift selector in Neutral. Throttle body must be free of carbon build-up and dirt. Repair any problems as necessary. If no problems exist, test is complete.

MISCELLANEOUS CONTROLS

Note. Although some of the controlled devices listed here are not technically engine performance components, they can affect driveability if they malfunction.

A/C CLUTCH RELAY OUTPUT

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS to ensure system is functioning properly. See the following: On 2.4L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

1. A/C Clutch Relay Operation
2. Ground Circuit Open
3. A/C Clutch
4. Fused B+ Circuit
5. A/C Clutch Relay

1. Ensure A/C system is properly charged with refrigerant. Turn ignition on. Using scan tool, actuate A/C clutch relay. Listen for clicking sound at A/C clutch relay. The A/C clutch relay is located in Integrated Power Module (IPM). IPM is located on left side of engine compartment, next to battery. (Scheme 79)and (Scheme 81). If clicking sound is not heard at A/C clutch relay, go to next step. If clicking sound is heard at A/C clutch relay, no problem is indicated at this time. Test is complete.
2. Turn ignition off. Disconnect A/C clutch connector. Measure resistance between ground and Black/Gray wire at A/C clutch harness connector. (Scheme 93) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black/Gray wire between A/C clutch and ground connection. Ground connection is located above starter.
3. Turn ignition on. Using scan tool, actuate the A/C clutch relay. Measure voltage between ground and Dark Blue/Yellow wire at A/C clutch harness connector. If voltage is 11 volts or less, go to next step. If voltage is more than 11 volts, replace A/C clutch.
4. Turn ignition off. Using a test light connected to ground, probe terminal No. 30 at A/C clutch relay socket in IPM. (Scheme 81) If test light illuminates, go to next step. If test light does not illuminate, check fuse No. 18 (15-amp) in IPM. If fuse is blown, check for cause of fuse to blow. Repair as necessary and replace fuse. If fuse is okay, replace IPM.
5. Turn ignition off. Disconnect IPM C3 connector. (Scheme 92) Measure resistance of Dark Blue/Yellow wire between A/C clutch harness connector and terminal No. 7 at IPM C3 harness connector. (Scheme 93)and (Scheme 94). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Blue/Yellow wire.
6. Reconnect IPM C3 harness connector. Measure resistance of Dark Blue/Yellow wire between terminal No. 87 at A/C clutch relay socket in IPM and A/C clutch harness connector. If resistance is less than 5 ohms, replace A/C clutch relay. If resistance is 5 ohms or more, replace IPM.

Scheme 92

Scheme 93

Scheme 94

Individual component testing information is not available from manufacturer. If ASD relay or wiring circuit failure exists, a DTC may be stored in PCM. Perform ASD related diagnostic test. See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

AUTOMATIC TRANSMISSION

For automatic transmission diagnostic information, see appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

PARK/NEUTRAL POSITION SWITCH (3-SPEED A/T)

Park/Neutral Position (PNP) switch is located on side of transaxle. (Scheme 95) Individual component testing information is not available from manufacturer. If PNP switch or wiring circuit failure exists, a DTC may be stored in PCM: See the following

1. On 2.4L, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157113-S04997432242003080500000) 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) in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

Scheme 95

RADIATOR FAN RELAY OUTPUT

Note. For circuit identification and wiring diagram, see WIRING DIAGRAMS . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-2 to ensure system is functioning properly. See the following: On 2.4L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN & VOYAGER - 2.4L article. On 3.3L and 3.8L, see POWERTRAIN VERIFICATION TEST VER-2 under VERIFICATION TESTS in SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER - 3.3L & 3.8L article.

1. Radiator Fan Relay Operation
2. Ground Circuit Open
3. Radiator Fan Relay Output Circuit
4. Radiator Fan Assembly

1. Turn ignition off. Disconnect radiator fan relay connector. Radiator fan relay is located near driver's side frame rail. (Scheme 96) Connect a jumper wire between Orange/Red and Dark Blue/Dark Green wires at radiator fan relay harness connector. If one or both radiator fans is not operating, go to next step. If both radiator fans operate, no problem is indicated at this time. Test is complete.
2. Disconnect jumper wire. Disconnect radiator fan connectors. Measure voltage between ground and Black/Dark Green wire at each radiator fan. If both resistance readings are less than 5 ohms, go to next step. If one or both resistance readings is 5 ohms or more, repair open in appropriate Black/Dark Green wire between radiator fan relay and ground connection. Ground connection is located near left headlight.
3. Connect a jumper wire between Orange/Red and Dark Blue/Dark Green wires at radiator fan relay harness connector. Measure voltage between ground and Dark Blue/Dark Green wire at each radiator fan. If both voltage readings are more than 10 volts, replace radiator fans. If one or both voltage readings is 5 ohms or less, repair open in appropriate Dark Blue/Dark Green wire between radiator fan and radiator fan relay.

Scheme 96

1. Remove starter relay from Integrated Power Module (IPM). IPM is located on left side of engine compartment, next to battery. (Scheme 79)
2. Measure resistance between terminals No. 85 and 86 on starter relay. (Scheme 97) If resistance is not 70-80 ohms, replace starter relay. If resistance is 70-80 ohms, go to next step.
3. Check for continuity between terminals No. 30 and 87 on starter relay. If continuity exists, replace starter relay. If no continuity exists, connect a jumper wire between negative battery terminal and terminal No. 85 on starter relay. Connect another jumper wire between positive battery terminal and terminal No. 86 on starter relay.
4. Starter relay should now be energized. Check for continuity between terminals No. 30 and 87 on starter relay. If continuity exists, starter relay is okay. If continuity does not exist, replace starter relay.

Scheme 97

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.

See also:
• DIAGNOSTIC PROCEDURE
• NO-START DIAGNOSIS
• TROUBLE SHOOTING - NO CODES - CARAVAN, TOWN & COUNTRY & VOYAGER
• POWERTRAIN VERIFICATION TEST VER-1
• BRAKE SWITCH
• DTC P0340: NO CAM SIGNAL AT PCM
• DTC P0320: NO CRANK REFERENCE SIGNAL AT PCM
• POWERTRAIN VERIFICATION TEST VER-2
• DIAGNOSTIC TROUBLE CODE DEFINITIONS
• DTC P1494: LEAK DETECTION PUMP SW OR MECHANICAL
• DTC P0443: EVAP PURGE SOLENOID CIRCUIT
• CHECKING FUEL DELIVERY
• FUEL PRESSURE REGULATOR
• FUEL PUMP MODULE
• WIRING DIAGRAMS
• PARK/NEUTRAL POSITION SWITCH (3-SPEED A/T)
• A/C CLUTCH RELAY OUTPUT
• RADIATOR FAN RELAY OUTPUT
• FUEL SYSTEM PRESSURE RELEASE