Chrysler Town, Dodge Caravan. Manual — part 655
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the Generator Field harness connector.
Using a 12-volt test connected to battery voltage, probe the (Z1) Gen Ground circuit
in the Generator Field harness connector.
Does the test light illuminate brightly?
All
Yes
→ Go To 4
No
→ Repair the open in the (Z1) Gen Field Ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
4
Turn the ignition off.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
Measure the voltage on the (K20) Gen Field Control circuit in the Generator Field
harness connector.
Is the voltage above 1.0 volts?
All
Yes
→ Repair the short to voltage in the (K20) Gen Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 5
5
Turn the ignition on.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
Measure the resistance between ground and the (K20) Gen Field Control circuit in
the Generator Field harness connector.
Is the resistance below 100 ohms?
All
Yes
→ Repair the (K20) Gen Field Control circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 6
6
Turn the ignition off.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K20) Gen Field Control circuit from the Generator
Field harness connector to the appropriate terminal of the special tool #8815.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 7
No
→ Repair the open in the (K20) Gen Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
7
NOTE: Before continuing, check the PCM connector terminals for corro-
sion, damage, or terminal push out. Repair as necessary.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
428
DRIVEABILITY - NGC
P0622-GENERATOR FIELD CONTROL CIRCUIT —
Continued
Symptom:
P0627-FUEL PUMP RELAY CIRCUIT
When Monitored and Set Condition:
P0627-FUEL PUMP RELAY CIRCUIT
When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts.
Set Condition:
An open or shorted condition is detected in the fuel pump relay control
circuit. One Trip Fault.
POSSIBLE CAUSES
FUEL PUMP RELAY INTERMITTENT OPERATION
INTERMITTENT CONDITION
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
INTEGRATED POWER MODULE
FUEL PUMP RELAY
IPM FUSE & RELAY CENTER
FUEL PUMP RELAY CONTROL CIRCUIT OPEN
FUEL PUMP RELAY CONTROL CIRCUIT SHORT TO GROUND
PCM
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRBIII
t, actuate the Fuel Pump Relay.
Is the Fuel Pump Relay operating?
All
Yes
→ Go To 2
No
→ Go To 3
2
Turn the ignition on.
With the DRBIII
t, actuate the Fuel Pump Relay.
Wiggle the wiring harness from the Fuel Pump Relay to the PCM while the relay is
actuating.
Did the Fuel Pump Relay stop when wiggling the wiring harness?
All
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Refer to the INTERMITTENT CONDITION symptom in the
Driveability category.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
429
DRIVEABILITY - NGC
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM.
Does the test light illuminate?
All
Yes
→ Go To 4
No
→ Go To 9
4
Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the Fuel Pump Relay Control
circuit in the IPM.
With the DRBIII
t, actuate the Fuel Pump Relay.
Does the test light flash on and off?
All
Yes
→ Replace the Fuel Pump Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To 5
5
Turn the ignition off.
Disconnect the IPM C3 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the Fuel Pump Relay Control
circuit in the IPM harness connector..
With the DRBIII
t, actuate the Fuel Pump Relay.
Does the test light flash on and off?
All
Yes
→ Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To 6
6
Turn the ignition off.
Disconnect the IPM C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Fuel Pump Relay Control circuit between the IPM C3
harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 7
No
→ Repair the Fuel Pump Relay Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7
Turn the ignition off.
Disconnect the IPM C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Fuel Pump Relay Control circuit in the IPM C3 harness
connector to ground.
Is the resistance below 5.0 ohms?
All
Yes
→ Repair the Fuel Pump Relay Control circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To 8
430
DRIVEABILITY - NGC
P0627-FUEL PUMP RELAY CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
8
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9
Turn the ignition off.
Disconnect the IPM C9 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM harness connector.
Does the test light illuminate?
All
Yes
→ Test Complete.
No
→ Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
431
DRIVEABILITY - NGC
P0627-FUEL PUMP RELAY CIRCUIT —
Continued
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