Chrysler Town, Dodge Caravan. Manual — part 670
TEST
ACTION
APPLICABILITY
8
Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIII
t, actuate the ASD Fuel System test.
Using a 12 volt test light connected to ground, probe the Fuel Pump Relay Output
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?
All
Yes
→ Go To 9
No
→ Go To 11
Caution: Stop All Actuations.
9
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Note: Check connectors - It is critical that the connector is free from any
signs of corrosion or deformities - Clean/repair as necessary.
Using a 12 - volt test light connected to battery voltage, probe the Fuel Pump ground
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?
All
Yes
→ Go To 10
No
→ Repair the open/high resistance in the fuel pump ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
10
If there are no possible causes remaining, view repair.
All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
11
Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
With a 12 volt test light connected to ground, probe the Fuel Pump Relay Fused B+
circuit in the IPM.
Does the test light illuminate?
All
Yes
→ Go To 12
No
→ Check for an open Fuel Pump fuse, repair cause of open. If OK,
replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
12
Turn the ignition off.
Disconnect the IPM harness connector.
Disconnect the Fuel Pump Module harness connector.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM
harness connector and the Fuel Pump Module connector.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 13
No
→ Repair the open fuel pump relay output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
488
STARTING
*ENGINE CRANKS DOES NOT START —
Continued
TEST
ACTION
APPLICABILITY
13
NOTE: Ensure all IPM harness connector are connected.
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Remove the Fuel Pump Relay from the IPM.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM and
the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?
All
Yes
→ Replace the Fuel Pump Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
489
STARTING
*ENGINE CRANKS DOES NOT START —
Continued
Symptom:
*NO CRANK CONDITION
POSSIBLE CAUSES
REPAIR MECHANICAL CONDITION
TRANSMISSION RANGE SENSOR
BATTERY CIRCUIT RESISTANCE TOO HIGH
IGNITION SWITCH OUTPUT CIRCUIT OPEN
STARTER RELAY CONTROL CIRCUIT OPEN
STARTER RELAY OUTPUT CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT (START) CIRCUIT OPEN
STARTER
STARTER MOTOR RELAY
STARTER RELAY
TEST
ACTION
APPLICABILITY
1
NOTE: Check all PCM powers and grounds before continuing.
NOTE: Ensure that SKIS is operating properly. Check the SKIM for DTC. If
a SKIM DTC(s) is present diagnose them first before continuing.
WARNING: MAKE SURE THE BATTERY IS DISCONNECTED, THEN WAIT
TWO MINUTES BEFORE PROCEEDING.
Turn the engine over by hand to ensure the engine is not seized.
Is the engine able to turn over?
All
Yes
→ Go To 2
No
→ Repair the mechanical condition preventing the starter motor
from cranking.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
2
Turn the ignition off.
Disconnect the PCM harness connectors.
Move the Gear selector through all gear positions, from Park to 1st and back.
While moving the gear selector through each gear, measure the resistance between
ground and the P/N Position Switch Sense circuit.
Did the resistance change from above 10.0 ohms to below 10.0 ohms?
All
Yes
→ Go To 3
No
→ Replace the Transmission Range Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
3
Turn the ignition off.
Check the Battery Cables for high resistance using the service information proce-
dure.
Did either Battery Cable have a voltage drop greater than 0.2 volt?
All
Yes
→ Repair the Battery circuit for high resistance.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To 4
490
STARTING
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
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.
Turn the ignition to the Start position.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
Output (Start) circuit in the appropriate terminal of special tool #8815.
Does the test light illuminate brightly?
All
Yes
→ Go To 5
No
→ Repair the Fused Ignition Switch (Start) circuit for an open or
high resistance.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
5
Turn ignition off.
Remove the Starter Relay from PDC.
WARNING: The Parking Brake must be engaged and the transmission must
be in Park for a vehicle equipped with an automatic transmission.
WARNING: The Starter may Engage in the next step. Keep away from
moving engine parts.
Briefly connect a jumper wire between Starter Relay B+ circuit and the Starter Relay
Output Circuits.
Turn the ignition to the crank position.
Did the Starter Motor crank the engine?
All
Yes
→ Go To 6
No
→ Go To 9
6
Turn the ignition off.
Remove the Starter Relay from the PDC.
Turn the ignition on.
Using a 12-volt test light, probe the Ignition Switch Output circuit in the Starter
Relay connector.
While observing 12-volt test light, hold ignition key in the start position.
Does the test light illuminate brightly?
All
Yes
→ Go To 7
No
→ Repair the Ignition Switch Output circuit for an open or high
resistance.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
7
Turn the ignition off.
Remove the Starter Relay from the PDC.
Disconnect the PCM harness connector.
Measure the Starter Relay Control circuit between the Relay terminal and the PCM
harness connector.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 8
No
→ Repair the Starter Relay Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
491
STARTING
*NO CRANK CONDITION —
Continued
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