Chrysler Town, Dodge Caravan. Manual — part 1166
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the IPM.
Connect a jumper wire between cavity 30 and cavity 87 in the ECM/PCM Relay
connector.
Using a 12-volt test light connected to ground, check the ECM/PCM Relay Output
circuit in ECM harness connector C1 cavities 4 and 5.
Did the test light illuminate for both circuits?
All
Yes
→ Go To 5
No
→ Repair the ECM/PCM Relay Output circuit(s) for an open.
Perform ROAD TEST VERIFICATION - VER-2.
5
Turn the ignition off.
Install a substitute relay in place of the ECM/PCM Relay.
Turn the ignition on.
With the DRB, attempt to communicate with the ECM.
With the DRB, can you communicate with the ECM?
All
Yes
→ Replace the ECM/PCM Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No
→ Go To 6
6
Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the IPM.
Connect a jumper wire between cavity 30 and cavity 87 in the ECM/PCM Relay
connector.
Using a 12-volt test light connected to ground, check the ECM/PCM Relay Output
circuit in ECM harness connector C1 cavities 4 and 5.
Does the test light illuminate brightly?
All
Yes
→ Go To 7
No
→ Repair the ECM/PCM Relay Control circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7
Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the IPM.
Connect a jumper wire between cavity 30 and cavity 87 of the ECM/PCM Relay
connector in the IPM.
Turn the ignition on.
Measure the voltage of the ECM/PCM Relay Control circuit.
Is the voltage above 1.0 volt?
All
Yes
→ Repair the ECM/PCM Relay Control circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No
→ Test Complete.
207
DRIVEABILITY - DIESEL
*CHECKING THE ECM POWER AND GROUND CIRCUITS —
Continued
Symptom:
*CHECKING THE EGR SYSTEM
POSSIBLE CAUSES
ECM/PCM RELAY OUTPUT CIRCUIT OPEN
EGR SOLENOID CONTROL CIRCUIT OPEN
EGR VALVE
VACUUM SUPPLY HOSE
TEST
ACTION
APPLICABILITY
1
Disconnect the Vacuum Supply Hose at the EGR solenoid.
Connect a vacuum gauge to the Vacuum Supply Hose.
Start the engine and allow the engine to idle.
Is the vacuum above 10 inches of mercury at idle?
All
Yes
→ Go To 2
No
→ Repair leaking or restricted Vacuum Supply Hose or faulty
Vacuum Supply Pump.
Perform ROAD TEST VERIFICATION - VER-2.
2
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the ECM/PCM Relay Output
circuit at the EGR Solenoid harness connector.
Is the test light on?
All
Yes
→ Go To 3
No
→ Repair the ECM/PCM Relay Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
3
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the EGR Solenoid Control circuit.
Is the resistance below 10.0 ohms?
All
Yes
→ Go To 4
No
→ Repair the EGR Solenoid Control circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
4
NOTE: The Vacuum Output Hose must not be leaking or restricted for the
result of this test to be valid.
Turn the ignition off.
Disconnect the Vacuum Supply and Vacuum Output Hoses in the EGR Solenoid
vacuum connector.
Connect the Vacuum Supply Hose to the Vacuum Output Hose.
Test drive the vehicle and observe vehicle performance.
Is there a power reduction on vehicle acceleration?
All
Yes
→ Test Complete.
No
→ Replace the EGR Valve.
Perform ROAD TEST VERIFICATION - VER-2.
208
DRIVEABILITY - DIESEL
Symptom:
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION
POSSIBLE CAUSES
ACTUATE THE HIGH AND LOW SPEED RADIATOR FAN WITH THE DRB
CHECK FOR RADIATOR FAN RELAY CONTROL DTCS
RADIATOR FAN RELAY NO. 1 OUTPUT CIRCUIT SHORTED TO VOLTAGE
RADIATOR FAN RELAY NO.2 AND NO.3 COMMON OUTPUT CIRCUIT SHORTED TO VOLTAGE
RADIATOR FAN NO. 1 CONTROL CIRCUIT SHORTED TO VOLTAGE
RADIATOR FAN RELAY NO. 1 FUSED B+ CIRCUIT OPEN
RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT CIRCUIT SHORTED TO GROUND
RADIATOR FAN RELAY NO. 3 FUSED B+ CIRCUIT OPEN
RADIATOR FAN RELAY NO.2 FUSED B+ CIRCUIT OPEN
RADIATOR FAN NO. 1 CONTROL CIRCUIT SHORTED TO GROUND
RADIATOR FAN RELAY NO. 2
RADIATOR FAN RELAY NO. 3
RADIATOR FAN RELAY NO.1
RADIATOR FAN RELAY NO.1 - INTERNAL SHORT TO VOLTAGE
RADIATOR FAN RELAY NO.2 OR NO.3 - INTERNAL SHORT TO VOLTAGE
RADIATOR FAN NO.1 - SHORTED
RADIATOR FAN NO.2 - SHORTED
RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT CIRCUIT OPEN FROM RELAY NO.
2
RADIATOR FAN RELAY NO. 3 GROUND CIRCUIT OPEN
RADIATOR FAN RELAY NO.1 OUTPUT CIRCUIT SHORTED TO GROUND
HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL CIRCUIT OPEN
RADIATOR FAN RELAY NO.1 OUTPUT CIRCUIT OPEN
RADIATOR FAN NO.1 CONTROL CIRCUIT OPEN
RADIATOR FAN RELAY NO.2 AND NO.3 COMMON OUTPUT CIRCUIT OPEN FROM RELAY NO. 3
RADIATOR FAN NO.1 - OPEN
RADIATOR FAN NO.2 - OPEN
209
DRIVEABILITY - DIESEL
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRBIII
t, read DTCs.
Are any Radiator Fan DTCs present?
All
Yes
→ Refer to symptom list for problems related to Radiator Fan
control.
Perform ROAD TEST VERIFICATION - VER-2.
No
→ Go To 2
2
NOTE: The engine temperature must not be hot enough to cause the
radiator fans to be on with the key off.
Turn the ignition off.
Observe the radiator fans with the key off.
Is either radiator fan running with the key off?
All
Yes
→ Go To 3
No
→ Go To 6
3
NOTE: The engine temperature must not be hot enough to cause the
radiator fans to be on with the key off.
Turn the ignition off.
Observe the radiator fans with the key off.
Which radiator fan(s) are running?
All
Fan 1 and Fan 2
Fan 2 Only
4
NOTE: The engine temperature must not be hot enough to cause the
radiator fans to be on with the key off.
Turn the ignition off.
Remove Radiator Fan Relay No.1.
Observe the radiator fans.
Did the radiator fans stop running?
All
Yes
→ Replace Radiator Fan Relay No.1.
Perform ROAD TEST VERIFICATION - VER-2.
No
→ Repair the Radiator Fan Relay No. 1 Output circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
5
NOTE: The engine temperature must not be hot enough to cause the
radiator fans to be on with the key off.
Turn the ignition off.
One at a time, remove Radiator Fan Relay No.2 and then Radiator Fan Relay No.3.
Observe the radiator fans after disconnecting each relay.
Did the radiator fan stop running?
All
Yes
→ Replace Radiator Fan Relay that caused the radiator fan to stop.
Perform ROAD TEST VERIFICATION - VER-2.
No
→ Repair the Radiator Fan Relay No. 2 and No.3 Common Output
circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
210
DRIVEABILITY - DIESEL
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION —
Continued
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