Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 37
(14) Check the vacuum connections at the throttle
body (Fig. 9).
(15) Ensure the AIS motor and TPS electrical con-
nectors are fully seated and not damaged (Fig. 9).
(16) Inspect the park/neutral switch wiring connec-
tion for damage. Ensure the automatic transmission
electrical connections are not damaged (Fig. 10).
Fig. 4 Coolant Temperature Sensor
Fig. 5 Fuel Pressure Regulator Vacuum Connection
Fig. 6 Oil Pressure Sending Unit Electrical Connec-
tion
Fig. 7 Canister Purge Solenoid Electrical Connector
Fig. 8 Vapor Canister
Fig. 9 Throttle Body Electrical and Vacuum Connec-
tions
.
FUEL SYSTEM
14 - 95
(17) Check the Vacuum Hose Harness connections at
the Intake Plenum (Fig. 11).
(18) Inspect the PCV system connections for damage
(Fig. 12).
(19) Inspect the crankshaft position sensor electrical
connector for damage (Fig. 13).
(20) Ensure the distance sensor electrical connector
is attached to the sensor and not damaged (Fig. 13).
(21) Verify the manifold absolute pressure (map)
sensor electrical connector is attached to the sensor
and not damaged (Fig. 14).
(22) Verify the engine ground strap is attached at
the engine and dash panel (Fig. 14). Inspect the strap
for corrosion or damage.
(23) Check the heated oxygen sensor electrical con-
nector for damage (Fig. 14).
Fig. 10 Automatic Transmission Electrical Connec-
tions
Fig. 11 Vacuum Hose Connections
Fig. 12 PCV System
Fig. 13 Crankshaft Sensor and Vehicle Distance
Sensor Electrical Connections
Fig. 14 MAP Sensor, Heated Oxygen Sensor, and
Ground Strap
14 - 96
FUEL SYSTEM
.
(24) Inspect the alternator wiring connections for
damage.
(25) Check the accessory drive belt tension.
(26) Check the 60-way electrical connection at the
Engine Controller (Fig. 15) for damage or spread
terminals. Verify that the 60-way connector is fully
inserted into the engine controller socket. Ensure the
wires are not stretched or pulled out of the connector.
(27) Ensure the relays are connected to the harness
connectors (Fig. 16 and Fig. 17) Inspect the connections
for damage.
(28) Inspect battery cable connections for corrosion.
(29) Check the power brake booster hose connection
(without anti-lock brake systems) (Fig. 18).
(30) Inspect the speed control vacuum connection
(Fig. 19).
(31) Inspect hose and wiring connections at fuel
pump. Check that wiring connector is making contact
with terminals on pump.
ON BOARD DIAGNOSTICS
The engine controller has been programmed to moni-
tor many different circuits of the fuel injection system.
If a problem is sensed with a monitored circuit often
enough to indicate an actual problem, the controller
stores a fault. If the problem is repaired or ceases to
exist, the engine controller cancels the Fault Code after
51 vehicle key on/off cycles.
Certain criteria must be met for a fault code to be
entered into the engine controller memory. The criteria
may be a specific range of engine RPM, engine tem-
perature, and/or input voltage to the engine controller.
It is possible that a fault code for a monitored circuit
may not be entered into memory even though a mal-
function has occurred. This may happen because one of
the fault code criteria for the circuit has not been met.
For example, assume that one of the fault code
criteria for the MAP sensor circuit is that the engine
must be operating between 750 and 2000 RPM to be
monitored for a fault code. If the MAP sensor output
circuit shorts to ground when engine RPM is above
2400 RPM (resulting in a 0 volt input to the engine
controller) a fault code will not be entered into memory.
This is because the condition does not occur within the
specified RPM range.
There are several operating conditions that the en-
gine controller does not monitor and set fault codes for.
Refer to Monitored Circuits and Non-Monitored Cir-
cuits in this section.
Fig. 15 Engine Controller
Fig. 16 Relay Identification
Fig. 17 A/C Clutch and A/C Fan Relays
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FUEL SYSTEM
14 - 97
Stored fault codes can be displayed either by cycling
the ignition key On - Off - On - Off - On, or through use
of the Diagnostic Readout Box II (DRB II). The DRB II
connects to the diagnostic connector in the vehicle (Fig.
15).
MONITORED CIRCUITS
The engine controller can detect certain fault condi-
tions in the fuel injection system.
Open or Shorted Circuit - The engine controller
can determine if the sensor output (input to controller)
is within proper range. Also, the controller can deter-
mine if the circuit is open or shorted.
Output Device Current Flow - The engine control-
ler senses whether the output devices are hooked up. If
there is a problem with the circuit, the controller
senses whether the circuit is open, shorted to ground,
or shorted high.
Oxygen Sensor - The engine controller can deter-
mine if the oxygen sensor is switching between rich
and lean once the system has entered closed loop. Refer
to Modes of Operation in this section for an explanation
of closed loop operation.
NON-MONITORED CIRCUITS
The engine controller does not monitor the following
circuits, systems and conditions that could have mal-
functions that result in driveability problems. Fault
codes may not be displayed for these conditions. How-
ever, problems with these systems may cause fault
codes to be displayed for other systems. For example, a
fuel pressure problem will not register a fault directly,
but could cause a rich or lean condition. This could
cause an oxygen sensor fault to be stored in the engine
controller.
Fuel Pressure - Fuel pressure is controlled by the
vacuum assisted fuel pressure regulator. The engine
controller cannot detect a clogged fuel pump inlet filter,
clogged in-line fuel filter, or a pinched fuel supply or
return line. However, these could result in a rich or
lean condition causing an oxygen sensor fault to be
stored in the engine controller.
Secondary Ignition Circuit - The engine control-
ler cannot detect an inoperative ignition coil, fouled or
worn spark plugs, ignition cross firing, or open spark
plug cables.
Engine Timing - The engine controller cannot de-
tect an incorrectly indexed timing chain, camshaft
sprocket and crankshaft sprocket. However, these
could result in a rich or lean condition causing an
oxygen sensor fault to be stored in the engine control-
ler.
Cylinder Compression - The engine controller
cannot detect uneven, low, or high engine cylinder
compression.
Exhaust System - The engine controller cannot
detect a plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions - The engine control-
ler cannot determine if a fuel injector is clogged, the
needle is sticking or the wrong injector is installed.
However, these could result in a rich or lean condition
causing an oxygen sensor fault to be stored in the
engine controller.
Excessive Oil Consumption - Although the engine
controller monitors exhaust stream oxygen content
when the system is in closed loop, it cannot determine
excessive oil consumption.
Fig. 18 Power Brake Booster Hose
Fig. 19 Speed Control Vacuum
14 - 98
FUEL SYSTEM
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