Content .. 1031 1032 1033 1034 ..

Dodge Caliber. Manual - part 1033

EGR SYSTEM

Refer to the symptom list and perform the CHECKING THE EGR SYSTEM test.

Were any problems found during the EGR System test?

Yes

>> Repair or replace as necessary.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

>> 4

FUEL SYSTEM LEAK

Turn the ignition off.

WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.

WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL
INJURY OR DEATH. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM.
Inspect the entire fuel system for leakage.

Is there any evidence of leakage?

Yes

>> Repair as necessary in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

>> Go To 5

FUEL SYSTEM CONTAMINATION

NOTE: Mixing any other fuels such as gasoline or kerosine can cause this symptom to occur.
Turn the ignition off.

Is the fuel contaminated?

Yes

>> Repair as necessary in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

>> Go To 6

CHECKING BOOST PRESSURE

Turn the ignition on.

NOTE: This test requires two people. One person to test drive the vehicle while a technician observes the
scan tool readings.
With the scan tool in Sensors, read and compare the Boost Pressure (PSI) with the Boost Pressure Desired/Set-
point (PSI) while test driving the vehicle under various load conditions such as idle, hard acceleration, and cruise.

NOTE: The Boost Pressure reading should directionally follow (trail) the Boost Pressure Desired/Setpoint
reading.

Does the Boost Pressure reading follow the Boost Pressure Desired/Setpoint reading?

Yes

>> Go To 7

>> Refer to the symptom CHECKING THE BOOST PRESSURE.

ENGINE ELECTRICAL DIAGNOSTICS - DIESEL

9 - 1419

FUEL INJECTOR CLASSIFICATION

NOTE: Each Fuel Injector is labeled with a code. This code determines the injector classification. Each
Injector classification must be programmed into the ECM using the scan tool.
Turn the ignition off.

Refer to the Service Information to locate each fuel injector label and check for the correct classification for each
fuel injector in the ECM.

Are all of the injectors classified correctly?

Yes

>> Go To 8

>> Using the scan tool, program the correct Fuel Injector classifications into the ECM.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

ENGINE COMPRESSION

Start and idle the engine.

With the scan tool, perform the Cylinder Compression Test.

Does the Cylinder Compression Test indicate low compression in any of the cylinders?

Yes

>> Using the Service Information, repair the engine as necessary to regain proper cylinder compression.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

>> Go To 9

FUEL INJECTOR

NOTE: An injector that sticks open can cause this symptom. A sticking injector will cause the engine to
misfire and emit excessive black smoke from the exhaust system.
Start and idle the engine.

With the scan tool, perform the Cylinder Fuel Quantity Correction Test.

NOTE: A problem injector will be indicated by a significant change in correction quantity as compared to
the rest of the injectors.

Are any of the injectors displaying a significant amount of injection quantity correction?

Yes

>> Using the Service Information, remove and inspect the Fuel Injectors for signs of damage or debris that

may cause the injector to stick. Sticking injectors may cause the combustion chamber to become black
and oil soaked. Replace Injector(s) as necessary.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

>> Go To 10

10.

ENGINE DRIVE BELT/CHAIN

Refer to the Service Information to ensure the Engine Drive Belt/Chain is installed correctly and the camshaft and
crankshaft gears are timed correctly.

Were any problems found?

Yes

>> Repair as necessary.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

>> Test Complete.

9 - 1420

ENGINE ELECTRICAL DIAGNOSTICS - DIESEL

11.

CHECKING THE SUPPLY SIDE FUEL DELIVERY SYSTEM

Refer to the appropriate Service Information and test for proper Fuel pressure and volume from the fuel tank to the
high pressure Fuel Injection Pump.

NOTE: The following is a list of problems that can cause fuel pressure to deviate from specification:
restricted fuel filter or fuel lines, air in fuel system, failed fuel sending unit, contaminated fuel.

Were there any problems with the Fuel Delivery System?

Yes

>> Repair as necessary in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

>> Test Complete

ENGINE ELECTRICAL DIAGNOSTICS - DIESEL

9 - 1421

*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION

For a complete wiring diagram Refer to Section 8W

Possible Causes

APP SENSOR 1

APP SENSOR 2

Diagnostic Test

APP SENSOR IDLE VOLTAGE

NOTE: If there are any Accelerator Pedal Position Sensor DTC’s active in the ECM, diagnose DTC’s before
continuing this test.

NOTE: The APP Sensor is a device that contains two separate potentiometer type sensors. Each sensor has
its own 5-volt supply circuit, sensor ground circuit and signal circuit. The APP Sensor no longer incorpo-
rates a low-idle switch.

NOTE: The APP Sensor 1 signal should always be double the voltage of the APP Sensor 2 signal.

NOTE: Ensure the accelerator pedal is free from any restriction or binding before continuing.
Turn the ignition on.

With the scan tool, read the APP Sensor 1 and APP Sensor 2 Volts with the accelerator pedal in the at rest position.

Does the scan tool display between 0.79 and 0.95 volt for sensor 1 and 0.39 and 0.48 volt for sensor
2?

Yes

>> Go To 2

>> Check the APP Sensor circuits for proper resistance. If o.k., replace the APP Sensor in accordance with

the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

APP SENSOR 1

While back probing, measure the voltage of the APP Sensor 1 Signal circuit at the ECM.

Monitor the voltmeter while slowly pressing the accelerator pedal completely down.

NOTE: APP signals are displayed in voltage and percentage on the scan tool. Although APP 1 voltage is
double APP 2 voltage, the percentage display of APP 1 and APP 2 should be within 2.5% of each other
during all phases of accelerator pedal travel.

Did the voltage increase smoothly with pedal travel?

Yes

>> Go To 3

>> Replace the Accelerator Pedal Position Sensor in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

APP SENSOR 2

While back probing, measure the voltage of the APP Sensor 2 Signal circuit at the ECM.

Monitor the voltmeter while slowly pressing the accelerator pedal completely down.

NOTE: APP signals are displayed in voltage and percentage on the scan tool. Although APP 1 voltage is
double APP 2 voltage, the percentage display of APP 1 and APP 2 should be equal during all phases of
accelerator pedal travel.

Did the voltage increase smoothly with pedal travel?

Yes

>> Go To 4

>> Replace the Accelerator Pedal Position Sensor in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

9 - 1422

ENGINE ELECTRICAL DIAGNOSTICS - DIESEL

Content .. 1031 1032 1033 1034 ..