Dodge Caliber. Manual - part 909

CHECKING THE FUEL PUMP INLET

Turn the ignition off.

WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or ser-
vicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow
these instructions can result in personal injury or death.
Remove the Fuel Pump Module and Fuel Tank Module (if equipped), inspect the Fuel Pump Inlet and the bottom of
the fuel tank for debris that could cause the fuel pump inlet to be plugged.

Is the Fuel Inlet Strainer plugged?

Yes

>> Repair/Replace as necessary.

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

>> Replace the Fuel Pump Module.

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

FUEL PUMP MODULE

NOTE: Before continuing visually and physically inspect the fuel delivery system for external leaks or dam-
age. Repair / replace as necessary.
Turn the ignition off.

) or #6631 (3/8

) fuel line adapter.

Install the fuel pressure gauge.

Start the engine and allow the fuel system to reach maximum pressure.

Turn the ignition off.

NOTE: Fuel specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and the
engine.

Monitor the fuel pressure gauge for a minimum of 5 minutes.

NOTE: The pressure should not fall below 241 KPa (35 psi).

Does the fuel pressure drop below 241 KPa (35 psi)?

Yes

>> Replace Fuel Pump Module.

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

>> Go to 5

FUEL INJECTOR(S)

Start the engine and allow the fuel system to reach maximum pressure.

Turn the ignition off.

NOTE: Fuel specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and fuel
pump module.

Monitor the fuel pressure gauge for a minimum of 5 minutes.

ENGINE ELECTRICAL DIAGNOSTICS - GPEC

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NOTE: The pressure should not fall below 241 KPa (35 psi)

Does the fuel pressure drop below 241 KPa (35 psi)?

Yes

>> Replace the leaking fuel injectors.

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

>> Check the fuel for contaminants.

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

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ENGINE ELECTRICAL DIAGNOSTICS - GPEC

*NO CRANK CONDITION

For a complete wiring diagram Refer to Section 8W.

Possible Causes

MECHANICAL CONDITION

BATTERY CIRCUIT RESISTANCE TOO HIGH

START ENABLE CIRCUITS

TRANSMISSION RANGE SENSOR

FUSED IGNITION SWITCH OUT (START)

CLUTCH INTERLOCK SWITCH SIGNAL CIRCUIT

CLUTCH INTERLOCK SWITCH GROUND CIRCUIT

CLUTCH INTERLOCK SWITCH

STARTER

Diagnostic Test

MECHANICAL CONDITION

NOTE: Check and diagnose all the TIPM DTC(s) before continuing.

NOTE: Ensure the Gear selector is in Park or Neutral.

NOTE: Verify the battery is fully charged and capable of passing a load test before continuing.

WARNING: Make sure the battery is disconnected, then wait two minutes before proceeding. Failure to do
so may result in personal injury or possible death.
Turn the engine over by hand to make sure the engine is not seized.

Is the engine able to turn over?

Yes

>> Go to 2

>> Repair the mechanical condition preventing the starter motor from cranking.

Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

EXCESSIVE RESISTANCE IN THE BATTERY CIRCUIT

Connect the battery cables.

Turn the ignition off.

Check the Battery Cables for excessive resistance using the service information procedure.

Did either Battery Cable have a voltage drop greater than 0.2 of a volt?

Yes

>> Repair the excessive resistance in the Battery circuit.

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

>> Go to 3

MANUAL TRANSMISSION

Is this vehicle equipped with a Manual transmission?

Yes

>> Go to 8

>> Go to 4

ENGINE ELECTRICAL DIAGNOSTICS - GPEC

9 - 925

START ENABLE OPERATION (ATX)

Turn ignition on.

Using a scan tool, monitor the Ignition Start Switch Sense.

Turn the ignition switch to the crank position.

Does the Ignition Start Switch Sense state change from Low to High?

Yes

>> Ensure the battery connection is clean and fastened tightly to the Starter. If OK, replace the Starter in

accordance with the Service Information.

>> Go to 5

START ENABLE CIRCUIT (ATX)

Turn the ignition off.

Disconnect the PCM harness connector.

Using a 12-volt test light connected to ground, probe the Start Enable
circuit in the PCM harness connector while holding the ignition key in
the start position.

Does the test light illuminate brightly?

Yes

>> Replace the PCM in accordance with the Service Informa-

tion.

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

>> Go to 6

TRANSMISSION RANGE SENSOR (ATX)

Turn the ignition off.

Test light still in the above position.

Disconnect the Transmission Range Sensor harness connector.

Using a jumper wire, connect one end to the Start Enable circuit and
the other to the Fused Ignition Switch Output (Start) circuit in the Trans-
mission Range Sensor harness connector.

Turn the ignition to the crank position.

Does the test light illuminate brightly?

Yes

>> Replace Transmission Range Sensor harness.

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

>> Go to 7

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ENGINE ELECTRICAL DIAGNOSTICS - GPEC

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