Chrysler Town, Dodge Caravan. Manual - part 595

TEST

ACTION

APPLICABILITY

Turn the ignition off.
Disconnect the TP Sensor harness connector.
Disconnect the MAP Sensor harness connector.
Disconnect the A/C Pressure Sensor harness connector.
Disconnect the EGR Solenoid harness connector.
Disconnect the PCM harness connectors.
Measure the resistance of the (F855) 5-volt Supply circuit in the TP Sensor harness
connector to ground.
Is the resistance below 5.0 ohms?

All

Yes

→ Repair the short to ground in the (F855) 5-Volt Supply Circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 5.

→ Go To 7

NOTE: Before Continuing: Disconnect the PCM harness connector and
check the related wiring terminals for corrosion, damage or terminal push
out. Repair as necessary.
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
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.

NOTE: The TP Sensor harness connector must be connected during this
test.
Disconnect the MAP Sensor harness connector.
Turn the ignition on.
Measure the (F855) 5-volt Supply circuit in the MAP Sensor harness connector.
Is the Voltage below 4.5 Volts?

All

Yes

→ Replace the TP Sensor.

Perform POWERTRAIN VERIFICATION TEST VER - 5.

→ Go To 9

188

DRIVEABILITY - SBEC

P1496-5 VOLT SUPPLY, OUTPUT TOO LOW —

Continued

TEST

ACTION

APPLICABILITY

WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRBIII

parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DRBIII

t Freeze Frame information. If possible, try to duplicate the

conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?

All

Yes

→ Repair as necessary

Perform POWERTRAIN VERIFICATION TEST VER - 5.

→ Test Complete.

189

DRIVEABILITY - SBEC

P1496-5 VOLT SUPPLY, OUTPUT TOO LOW —

Continued

Symptom:

P1594-CHARGING SYSTEM VOLTAGE TOO HIGH

When Monitored and Set Condition:

P1594-CHARGING SYSTEM VOLTAGE TOO HIGH

When Monitored:

The engine running. The engine speed greater than 380 RPM.

Set Condition:

Battery voltage is 1 volt greater than desired system voltage.

POSSIBLE CAUSES

TARGET VOLTAGE DIFFERS FROM BATTERY VOLTAGE

INTERMITTENT CONDITION

(K20) GENERATOR FIELD DRIVER CIRCUIT SHORTED TO GROUND

GENERATOR FIELD

PCM

TEST

ACTION

APPLICABILITY

Note: Battery must be fully charged.
Note: Generator Belt tension and condition must be checked before con-
tinuing.
Turn the ignition on.
With DRBIII

t, actuate the Generator Field Driver.

With a 12-volt test light connected to ground, backprobe the (K20) Generator Field
Driver circuit in the back of Generator harness connector.
Does the test light illuminate brightly and flash?

All

Yes

→ Go To 2

→ Go To 5

With DRBIII

t, stop all actuation.

Turn the ignition on.
With DRBIII

t, read the Target Charging voltage.

Is the Target Charging voltage above 13 volts?

All

Yes

→ Go To 3

→ Go To 4

Start the engine.
With the DRBIII

t, manually set the engine speed to 1600 RPM.

With DRBIII

t, read both the Battery voltage and the Target Charging voltage.

Compare the Target Charging Voltage to the Battery Voltage reading.
Monitor voltage for 5 minutes, if necessary. Look for a 1.0 volt difference or more.
Was there more than a 1.0 volt difference?

All

Yes

→ Replace the Powertrain Control Module in accordance with the

Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.

→ Go To 4

190

DRIVEABILITY - SBEC

TEST

ACTION

APPLICABILITY

parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DRBIII

t Freeze Frame information. If possible, try to duplicate the

All

Yes

→ Repair as necessary

Perform POWERTRAIN VERIFICATION TEST VER - 3.

→ Test Complete.

Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Generator Field harness connector.
Measure the resistance of the (K20) Generator Field Driver circuit from the PCM
harness connector to ground.
Is the resistance below 5.0 ohms?

All

Yes

→ Repair the short to ground in the (K20) Generator Field Driver

circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.

→ Go To 6

Turn the ignition off.
Disconnect the Generator Field harness connector.
Measure resistance of the Generator Field Driver terminal pin of the Generator to
ground.
Is the resistance below 5.0 ohms?

All

Yes

→ Repair or replace the shorted Generator as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 3.

→ Go To 7

NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
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.

191

DRIVEABILITY - SBEC

P1594-CHARGING SYSTEM VOLTAGE TOO HIGH —

Continued

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