Dodge Neon / Neon SRT-4. Manual - part 524

NOTE (NGC)

The PL is equipped with the Powertrain
Control Module and Transmission Control
Module combined in a single control module.
This

module

the

Next

Generation

Controller (NGC) for DaimlerChrysler and will
be referred to as the Powertrain Control
Module (PCM).
The PCM has four color coded connectors C1
through C4, (C1 - BLK, C2 - ORANGE, C3 -
WHITE, C4 - GREEN), with each connector
containing 38 pins.
Two tools are required to diagnose and repair
the PCM terminals and harness connectors:

1. Miller #3638 Terminal Removal Pick must

used

release

the

connector

terminals

harness

and

connector

damage will occur.

2. Miller #8815 Pinout Box must be used to

probe the PCM terminals or terminal
damage will occur.

1.0

INTRODUCTION

The procedures contained in this manual include

specifications, instructions, and graphics needed to
diagnose the PCM Powertrain System. The diag-
nostics in this manual are based on the failure
condition or symptom being present at time of
diagnosis.

Please follow the recommendations below when

choosing your diagnostic path.

1. First make sure the DRBIII

t is communicating

with the appropriate modules; ie., if the DRBIII

displays a No Response condition, you must
diagnose this first before proceeding.

2. Read DTC’s (diagnostic trouble codes) with the

DRBIII

3. If no DTC’s are present, identify the customer

complaint.

4. Once the DTC or customer complaint is identi-

fied, locate the matching test in the Table of
Contents and begin to diagnose the symptom.

All component location views are in Section 8.0.

All connector pinouts are in Section 9.0. All system
schematics are in Section 10.0.

An * placed before the symptom description indi-

cates a customer complaint.

When repairs are required, refer to the appropri-

ate service information for the proper removal and
repair procedure.

Diagnostic procedures change every year. New

diagnostic systems may be added; carryover sys-

tems may be enhanced. READ THIS DIAGNOSTIC
INFORMATION BEFORE TRYING TO DIAG-
NOSE A VEHICLE CODE. It is recommended that
you review the entire diagnostic information to
become familiar with all new and changed diagnos-
tic procedures.

If you have any comments or recommendations

after reviewing the diagnostic information, please
fill out the form at the back of the book and mail it
back to us.

1.1

SYSTEM COVERAGE

This diagnostic procedures manual covers the

2005 PL vehicle equipped with the 2.0L/2.4L and
2.4L Turbo Engines.

1.2

SIX-STEP TROUBLESHOOTING
PROCEDURE

Diagnosis of the powertrain control module

(PCM) is done in six basic steps:

•

verification of complaint

•

verification of any related symptoms

•

symptom analysis

•

problem isolation

•

repair of isolated problem

•

verification of proper operation

2.0

IDENTIFICATION OF
SYSTEM

The Powertrain Control Module (PCM) monitors

and controls:

•

Fuel System

•

Idle Air Control System

•

Ignition System

•

Charging System

•

Speed Control System

•

Cooling system

3.0

SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION

3.1

GENERAL DESCRIPTION

These Sequential Fuel Injection (SFI) engine sys-

tems have the latest in technical advances. The
OBDII/EOBD diagnostics incorporated with the
Powertrain Control Module (PCM) are intended to
assist the field technician in repairing vehicle prob-
lems by the quickest means.

GENERAL INFORMATION

3.2

FUNCTIONAL OPERATION

3.2.1

FUEL CONTROL

The PCM controls the air/fuel ratio of the engine

by varying fuel injector on time. Air flow is calcu-
lated using the speed density method using enigne
speed, manifold absolute pressure, and air temper-
ature change.

Different fuel calculation strategies are used de-

pending on the operational state of the engine.
During crank mode, a longer pulse width fuel pulse
is delivered followed by fuel pulses determined by a
crank time strategy. Cold engine operation is deter-
mined via an open loop strategy until the O2
sensors have reached operating temperature. At
this point, the strategy enters a closed loop mode
where fuel requirements are based upon the state of
the O2 sensors, engine speed, MAP, throttle posi-
tion, air temperature, battery voltage, and coolant
temperature.

3.2.2

ON-BOARD DIAGNOSTICS

The PCM has been programmed to monitor many

different circuits of the fuel injection system. This
monitoring is called on-board diagnosis.

Certain criteria, or arming conditions, must be

met for a trouble code to be entered into the PCM
memory. The criteria may be a range of: engine rpm,
engine temperature, and/or input voltage to the
PCM. If a problem is sensed with a monitored
circuit, and all of the criteria or arming conditions
are met, then a trouble code will be stored in the
PCM.

It is possible that a trouble code for a monitored

circuit may not be entered into the PCM memory
even though a malfunction has occurred. This may
happen because one of the trouble code criteria have
not been met.

The PCM compares input signal voltages from

each input device with specifications (the estab-
lished high and low limits of the range) that are

programmed into it for that device. If the input
voltage is not within specifications and other trou-
ble code criteria are met, a trouble code will be
stored in the PCM memory.

The On Board Diagnostics have evolved to the

second Generation of Diagnostics referred to as
OBDII/EOBD. These OBDII/EOBD Diagnostics
control the functions necessary to meet the require-
ments of California OBDII, Federal OBD regulation
and European regulation. These requirements spec-
ify the inclusion of a Malfunction Indicator Light
(MIL) located on the instrument panel. The purpose
of the MIL is to inform the vehicle operator in the
event of a malfunction of any emission system or
component failure.

MIL Lamp Strategy
I/M Readiness OK to test = Key On Engine OFF

– MIL Lamp will remain on until the engine is
started or Ignition is turned off.

I/M not ready for testing = Key On Engine OFF

– MIL Lamp on solid for (15) seconds then MIL
Lamp will flash on/off for (5) seconds then it will
remain on until the vehicle is started or the Ignition
is turned off.

GENERAL INFORMATION

OBD II/EOBD MONITOR INFORMATION

Comprehensive

Major Monitors

Components

Non Fuel Control

Fuel Control

Monitor

& Non Misfire

& Misfire

Run constantly

Run Once Per Trip

Run Constantly

Includes All Engine Hardware

Monitors Entire Emission

Monitors Entire System

- Sensors, Switches,

System

Solenoids, etc.

One Trip Faults - Turns On

Two Trip Faults - Turns On

The MIL and Sets DTC After

One Failure

Two Consecutive Failures

Priority 3

Priority 1 or 3

Priority 2 or 4

All Checked For Continuity

Done Stop Testing = Yes

Fuel Control Monitor

Open

Monitors Fuel Control

Short To Ground

Oxygen Sensor Heater

System For:

Short To Voltage

Oxygen Sensor Response

Fuel System Lean
Fuel System Rich

Inputs Checked For

Requires 3 Consecutive

Rationality

Catalytic Converter

Fuel System Good Trips

Efficiency Except EWMA

Extinguish The MIL

Outputs Checked For

- up to 6 tests per trip

Functionality

and a one trip fault

Misfire Monitor

Evaporative Emission

Monitors For Engine Misfire

System

at:

1000 RPM Counter

(Type B)

**200 RPM Counter

(Type A)

Requires 3 Consecutive

Global/Alternate Good Trips

Global Good Trips

Misfire Good Trips

to Extinguish the MIL*

To Extinguish the MIL

*40 Warm Up Cycles are required to erase

**Type A misfire is a two

DTC’s

after

the MIL has been extinguished.

trip failure. The MIL will
illuminate and blink at
the first failure.

GENERAL INFORMATION

OBDII Monitor Run Process
NGC Vehicle

The following procedure has been established to

assist Technicians in the field with enabling and
running OBDII Monitors. The order listed in the
following procedure is intended to allow the techni-
cian to effectively complete each monitor and to set
the CARB Readiness Status in the least time pos-
sible.

**NOTE**

A. Once the monitor run process has begun, do

not turn off the ignition. By turning the igni-
tion key off, monitor enabling conditions will
be lost. Only the 02 Heater Monitor runs after
key off.

B. By performing a Battery Disconnect, or Se-

lecting Erase DTCs, the CARB Readiness and
all

additional

OBD

information

will

cleared.

Monitor Preliminary Checks:

1. Plug a DRBIII into the vehicle’s DLC.

2. Turn the ignition, KEY ON–ENGINE OFF.

Watch for MIL lamp illumination during the
bulb check. MIL lamp must have illuminated, if
not, repair MIL lamp.

3. On the DRB III Select #1 DRB III Standalone.

4. Select #1 1998-2005 Diagnostics

5. Select #1 Engine

6. Select #2 DTCs and Related Functions

7. Select #1 Read DTCs

*Verify that No Emissions Related DTCs are
Present.
*If an Emissions DTC is Present, the OBD II
Monitors may not run and the CARB Readiness
will not update.
*The Emissions related DTC, will need to be
repaired, then cleared. By clearing DTCs, the
OBD Monitors will need to be run and completed
to set the CARB Readiness Status.

8. Return to Engine Select Function Menu and

Select #9, OBD II Monitors.

9. Select #2 CARB Readiness Status.

Do all the CARB Readiness Status Locations read
YES?

*YES, then all monitors have been completed and
this vehicle is ready to be I/M or Emission Tested.
*NO, then the following procedure needs to be
followed to run/complete all available monitors.

**NOTE**
A. Only the monitors, which are not YES in the

CARB Readiness Status, need to be completed.

B. Specific criteria need to be met for each monitor.

Each monitor has a Pre-Test screen to assist in

running the monitor. For additional informa-
tion, refer to the Chrysler Corporation Technical
Training Workbook title On Board Diagnostics,
part number 81-699-97094.

The most efficient order to run the monitors has
been outlined below, including suggestions to aid
the process.

A. NATURAL VACUUM LEAK DETECTION WITH
PURGE MONITOR

This monitor requires a cool down cycle, usually

an overnight soak for at least 8 hours without the
engine running. The ambient temperature must
decrease overnight – parking the vehicle outside is
advised. To run this test the fuel level must be
between 15-85% full. For the monitor run condi-
tions select the EVAP MON PRE-TEST in the
DRB III

t, OBD II Monitors Menu. The Purge mon-

itor will run if the small leak test reports a pass.
Criteria for NVLD monitor.

1. Engine off time greater than one hour

2. Fuel Level between 15% and 85%

3. Start Up ECT and IAT within 10°C (18°F).

4. Vehicle started and run until Purge Monitor

reports a result.

NOTE: If the vehicle does not report a result
and the conditions were correct, it may take
up to two weeks to fail the small leak monitor.
DO NOT use this test to attempt to determine
a

fault.

Use

the

appropriate

service

information procedure for finding a small
leak. If there are no faults and the conditions
are correct this test will run and report a
pass. Note the Small leak test can find leaks
less than 10 thousandths of an inch. If a
small leak is present it takes approximately
one week of normal driving to report a failure.

B. CATALYST/O2 MONITOR

With NGC, Catalyst and O2 Monitor information

are acquired and processed at the same time. Most
vehicles will need to be driven at highway speed
(<50 mph) for a few minutes. Some trucks run the
monitor at idle in drive. If the vehicle is equipped
with a manual transmission, using 4

gear may

assist in meeting the monitor running criteria. For
the monitor run conditions, select the BANK 1 CAT
MON PRE-TEST in the DRB III

t, OBD II Monitors

Menu.

C. EGR MONITOR

The EGR monitor now runs in a closed throttle

decel or at idle on a warm vehicle. However, it is
necessary to maintain the TPS, Map and RPM
ranges to allow the monitor to complete itself. For

GENERAL INFORMATION

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