Dodge Sprinter. Manual — part 516
Symptom:
*CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS
POSSIBLE CAUSES
FUEL PRESSURE SOLENOID RESISTANCE
OPEN CIRCUITS
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the Fuel Pressure Solenoid harness connector.
Disconnect the ECM harness connectors.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires. Repair as necessary.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals. Repair as necessary.
Measure the resistance of both Fuel Pressure Solenoid circuits between the ECM
harness connector and the Fuel Pressure Solenoid harness connector.
Is the resistance below 10.0 ohms for both measurements?
All
Yes
→ Go To 2
No
→ Repair open circuit(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
2
Turn the ignition off.
Disconnect the Fuel Pressure Solenoid harness connector.
Measure the resistance of the Fuel Pressure Solenoid.
Is the resistance between 3.5 and 5.5 ohms?
All
Yes
→ Test Complete.
No
→ Replace the Fuel Pressure Solenoid.
Perform ROAD TEST VERIFICATION - VER-2.
233
DRIVEABILITY - DIESEL
Symptom:
*CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS
POSSIBLE CAUSES
OPEN CIRCUITS
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the Fuel Quantity Solenoid harness connector.
Disconnect the ECM harness connectors.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires. Repair as necessary.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals. Repair as necessary.
Measure the resistance of both Fuel Quantity Solenoid circuits between the ECM
harness connector and the Fuel Quantity Solenoid harness connector.
Is the resistance below 10.0 ohms for both measurements?
All
Yes
→ Test Complete.
No
→ Repair open circuit(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
234
DRIVEABILITY - DIESEL
Symptom:
*CHECKING THE POWER AND GROUNDS
POSSIBLE CAUSES
CHECKING THE ENGINE CONTROL RELAY SYSTEM
EC RELAY OUTPUT CIRCUIT
ECM GROUND CIRCUIT(S) OPEN
ECM OUTPUT SHORTED - FUSE 16
ENGINE CONTROL MODULE
ENGINE CONTROL RELAY
ENGINE CONTROL RELAY B+ SUPPLY
ENGINE CONTROL RELAY CONTROL CIRCUIT OPEN
ENGINE CONTROL RELAY CONTROL CIRCUIT SHORT TO VOLTAGE
ENGINE CONTROL RELAY OUTPUT CIRCUIT(S) OPEN
ENGINE CONTROL RELAY OUTPUT CKT SHORTED TO GROUND FUSE #16
ENGINE CONTROL RELAY OUTPUT CKT SHORTED TO GROUND FUSE #17
IGNITION SWITCH START OUTPUT CIRCUIT OPEN
IGNITION SWITCH START/RUN OUTPUT CIRCUIT OPEN
SHORTED COMPONENT
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the ECM harness connectors.
Using a 12-volt test light connected to 12-volts, check each of the ECM ground
circuits in ECM harness connector C2 cavities 2, 4 and 6.
Did the test light illuminate brightly for each cavity?
All
Yes
→ Go To 2
No
→ Repair the ECM Ground circuit(s) for an open.
Perform ROAD TEST VERIFICATION - VER-2.
2
Turn the ignition off.
Disconnect the ECM harness connectors.
Turn the ignition switch to the Start position.
Using a 12-volt test light connected to ground, check the Fused Ignition Switch Start
Output circuit in ECM C2 harness connector cavity 36.
Does the test light illuminate brightly?
All
Yes
→ Go To 3
No
→ Repair the Ignition Switch Start Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
235
DRIVEABILITY - DIESEL
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the ECM harness connectors.
Turn the ignition switch to the Start position.
Using a 12-volt test light connected to ground, check the Fused Ignition Switch
Start/Run Output circuit in ECM C2 harness connector cavity 19.
Repeat the previous step with the ignition switch in the Run position.
Does the test light illuminate brightly in the Start and Run positions?
All
Yes
→ Go To 4
No
→ Repair the Ignition Switch Start/Run Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
4
Turn the ignition off.
Remove the Engine Control Relay from Fuse Block No. 1.
Using a 12-volt test light connected to 12-volts, check the Engine Control Relay
Control circuit in the Engine Control Relay connector in Fuse Block No. 1.
Turn the ignition on.
Does the test light illuminate?
All
Yes
→ Go To 5
No
→ Go To 14
5
Turn the ignition off.
Remove and inspect Fuse #17 from Fuse Block No.1.
Is the fuse open?
All
Yes
→ Go To 6
No
→ Go To 8
6
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the EGR Valve harness connector.
Disconnect the Boost Pressure Solenoid harness connector.
Remove the Starter Relay.
Remove the Lift Pump Relay.
Install a good fuse in place of Fuse #17 in Fuse Block No.1
Connect a jumper wire between ground and the Engine Control Relay Control circuit
in ECM C2 harness connector cavity 44.
Turn the ignition on.
Remove and inspect Fuse #17 in Fuse Block No. 1.
Is the fuse open?
All
Yes
→ Repair the Engine Control relay Output circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
No
→ Go To 7
7
NOTE: A short circuit exists in one of the following: Lift Pump Relay, Starter
Relay, EGR Valve, Boost Pressure Servo Motor or ECM.
View repair.
All
Yes
→ Using the Service Information wiring check the listed components
for short circuits. Replace the shorted component as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
236
DRIVEABILITY - DIESEL
*CHECKING THE POWER AND GROUNDS —
Continued
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