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Dodge Caravan ES 1991 - 1991 ENGINE PERFORMANCE Self-Diagnostics - 2.5L Gasoline
Dodge Caravan ES 1991 - INTRODUCTION
If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, proceed with self-diagnostics. If no fault codes or only pass codes are present after entering self-diagnostics, proceed to H - GAS TESTS W/O CODES article for diagnosis by symptom (i.e. ROUGH IDLE, NO START, etc.).
Dodge Caravan ES 1991 - MODEL IDENTIFICATION
Dodge Caravan ES 1991 VEHICLE BODY IDENTIFICATION
Model Name Body Type Caravan, Voyager AS Dakota AN
NOTE: Fault code charts may contain references to body types not covered in this article.
Dodge Caravan ES 1991 - SELF-DIAGNOSTIC SYSTEM SYSTEM DIAGNOSIS
The self-diagnostic capabilities of this system, if properly utilized, can simplify testing. The Single-Board Engine Controller (SBEC) monitors several different engine control system circuits.
If a problem is sensed with a monitored circuit, a fault code is stored in the SBEC, the CHECK ENGINE light illuminates, and SBEC enters limp-in mode. In limp-in mode, SBEC compensates for component failure by substituting information from other sources. This allows vehicle operation until repairs can be made.
Once fault codes are known, refer to FAULT CODES table in this article to determine the questionable circuit. Test circuits and repair or replace components as required. If problem is repaired or ceases to exist, the SBEC cancels that fault code after approximately 50 ignition on-off cycles. To clear fault codes, see CLEARING FAULT CODES in this article.
A specific fault code is the result of a particular system failure, but it DOES NOT indicate that cause of failure is necessarily within system. The fault code DOES NOT condemn any specific component; it pinpoints a probable malfunctioning area.
Dodge Caravan ES 1991 - Hard Failures
Hard failures cause CHECK ENGINE light to illuminate and remain on until the malfunction is repaired. If light comes on and remains on (light may flash) during vehicle operation, cause of malfunction must be determined using diagnostic (code) charts. If a sensor fails, SBEC will use a substitute value in its calculations, allowing engine operation in limp-in mode. In this condition, vehicle will run but driveability may be poor.
NOTE: A start counter (key counter) appears at bottom of fault message on DRB-II to show number of engine starts since fault code last occurred. This helps determine if fault is intermittent. As an example, if DRB-II displays 0 STARTS SINCE ERS, it indicates zero engine starts since fault occurred, and fault code is a hard failure. If start counter (key counter) shows more than zero engine starts since fault last occurred, then fault code is an intermittent failure.
Dodge Caravan ES 1991 - Intermittent Failures
Intermittent failures may cause CHECK ENGINE light to flicker or illuminate and go out after the intermittent fault goes away. However, the corresponding fault code will be retained in SBEC memory.
If related fault does not reoccur within a certain time frame, fault code will be erased from SBEC memory. Intermittent failures can be caused by a defective sensor, connector, or wiring-related problems. See INTERMITTENTS in H - GAS TESTS W/O CODES article.
Dodge Caravan ES 1991 - DIAGNOSTIC PROCEDURE
To obtain fault codes, see RETRIEVING FAULT CODES in this article. If fault codes are NOT present and/or Diagnostic Readout Box II (DRB-II) is used, proceed to one of the following tests.
- Go to NO START TEST 1A (NS-1A) chart if a no-start condition exists, or engine stalls after start-up. Perform indicated VERIFICATION PROCEDURE chart after repairs. Ensure charts apply to engine being tested.
- Go to DRIVEABILITY TEST 1A (DR-1A) chart if engine runs but has performance problems. Perform indicated VERIFICATION PROCEDURE chart after repairs. Ensure charts apply to engine being tested.
NOTE: When using trouble shooting charts for diagnosis, DO NOT skip any steps in chart, or incorrect diagnosis may result.
Before proceeding with diagnosis, the following precautions must be followed:
- Vehicle must have a fully charged battery, and functional charging system.
- Probe SBEC connector from pin side. DO NOT backprobe SBEC connector.
- DO NOT cause short circuits when performing electrical tests. This will set additional fault codes, making diagnosis of original problem more difficult.
- DO NOT use a test light in place of a voltmeter.
- When checking for spark, ensure coil wire is NO more than 1/4" from ground. If coil wire is more than 1/4" from ground, damage to vehicle electronics and/or SBEC may result.
- DO NOT prolong testing of fuel injectors, or engine may hydrostatically (liquid) lock.
- Always repair lowest fault code number (CHECK ENGINE light), or first fault displayed (DRB-II) first.
- Always perform VERIFICATION PROCEDURE test after repairs are made.
- Always disconnect DRB-II after use.
- Always disconnect DRB-II before charging battery.
Dodge Caravan ES 1991 - RETRIEVING FAULT CODES
NOTE: Manufacturer recommends using DRB-II (Diagnostic Readout Box-II, C-4805) to diagnose the system. CHECK ENGINE light function can be used, but has limited diagnostic usage. Unable to locate this exact procedure. Chuck said it was okay to leave in.
Dodge Caravan ES 1991 - Check Engine Light Method
- Start engine (if possible). Move transmission shift lever through all gear positions, ending in Park. Turn A/C switch on, then off (if equipped).
- Turn engine off. Without starting engine again, turn ignition on, off, on, off, and on. Record 2-digit fault codes as displayed by the flashing CHECK ENGINE light.
- For example, Code 23 is displayed as flash, flash, 4-second pause, flash, flash, flash. After a slightly longer pause, other codes stored are displayed in numerical order.
- Once CHECK ENGINE light begins to flash fault codes, it cannot be stopped. If you lose count, it will be necessary to start over. Code 55 indicates end of fault code display.
- - FAULT CODES table to translate fault code number to a system fault description (display on DRB-II). Once fault code description is obtained, refer to appropriate NO START TEST 1A (NS-1A) or DRIVEABILITY TEST 1A (DR-1A) trouble shooting chart for additional testing procedures.
- As an example, a 3.0L engine starts and runs, but has a driveability problem, and CHECK ENGINE light indicates a Code 14. - FAULT CODES table to translate fault code number to a system fault description (display on DRB-II).
- When system fault description (display on DRB-II) is obtained, refer to appropriate DRIVEABILITY TEST 1A (DR-1A) trouble shooting chart, since vehicle has a driveability problem, for more testing procedures. Select fault message and corresponding test from table, and proceed to appropriate trouble shooting chart. Test procedure may vary depending whether fault code is a hard or intermittent failure.
NOTE: When using trouble shooting charts for diagnosis, DO NOT skip any steps in chart, or incorrect diagnosis may result.
NOTE: The DRB-II can also be used to perform the following: display the state or values of sensors, inputs/outputs and components, allow various outputs such as valves and hydraulics to be tested, and reset Emission Maintenance Reminder (EMR) functions. See OPERATING MODES and EMISSION MAINTENANCE REMINDER (EMR) in this article.
Dodge Caravan ES 1991 - DRB-II Method
- Turn ignition off. Attach DRB-II Tester (C-4805) to diagnostic connector.
Dodge Caravan ES 1991 DIAGNOSTIC CONNECTOR LOCATIONS (1)
Application Location Caravan, Voyager In Engine Compartment, Near SBEC Dakota In Engine Compartment, On Right Corner Of Firewall (1) See Fig. 1 -5. 
Fig. 1: Dodge Caravan ES 1991 - Component Locations - Identifying Diagnostic Connector Terminals
Fig. 2: Dodge Caravan ES 1991 - Component Locations - Locating Diagnostic Connector (Caravan)
Fig. 3: Dodge Caravan ES 1991 - Component Locations - Locating Diagnostic Connector (Voyager)
Fig. 4: Dodge Caravan ES 1991 - Component Locations - Locating Diagnostic Connector (Dakota) - Start engine (if possible). Move transmission shift lever through all positions, ending in Park. Turn A/C switch on, then off (if equipped). Turn engine off. Without starting engine again, turn ignition on. DO NOT touch keypad on DRB-II during power-up sequence, or an error will result. The copyright date and diagnostic program will be displayed briefly.
- If DRB-II screen is blank, or if an error message appears, proceed to DRB-II PROBLEMS & ERROR MESSAGES in this article. The following are possible error messages that may appear: BAD FRAMING, BAD OP CODE, CARTRIDGE ERROR, COMMAND REJECTED, HIGH BATTERY, KEYPAD TEST FAILURE, LOW BATTERY, NO RESPONSE or RAM TEST FAILURE.
- After a few seconds, display will change to read as follows: DRB-II, 1) VEHICLES TESTED, or 2) HOW TO USE. Press ENTER button immediately. Press the down arrow twice. Display will now read as follows: DRB-II, 2) HOW TO USE, 3) CONFIGURE, and 4) SELECT SYSTEM.
- Select No. 4 (SELECT SYSTEM) to enter the diagnostic system. Display will read as follows: SELECT SYSTEM, 1) ENGINE, and 2) TRANSMISSION. Select No. 1 (ENGINE) to enter the engine system part of the DRB-II program. Display will change to read as follows: 1991 XX, XXXX EMISSIONS, AUTOMATIC TRANS, SBEC XX,#XXXX-A.
NOTE: Display may vary slightly depending on engine package being diagnosed. - After a few seconds, display will change to read as follows: AIR COND, 1) WITH A/C, and 2) WITHOUT A/C. Press ENTER button to change display immediately. Select No. 1 or No. 2 as appropriate for vehicle being tested.
- Display will now read as follows: ENGINE SYSTEM, 1) FUEL/IGNITION, and 2) CHARGING. Select No. 1 (FUEL/IGNITION) to bring up menu of test categories for the fuel/ignition system. Display will change to read as follows: FUEL/IGN MENU, 1) SYSTEM TEST, and 2) READ FAULTS.
- Press the down arrow 3 times to view rest of menu. Display will read as follows: FUEL/IGN MENU, 3) STATE DISPLAY, 4) ACTUATOR TEST, and 5) ADJUSTMENTS. To read fault codes, select No. 2 (READ FAULTS).
- If no fault code exists, display will read as follows: NO FAULTS DETECTED. If fault codes exist, display will show number of faults detected, such as 1 of 3 faults, and fault message. This is the fault counter. Below the fault message, the start counter (key counter) will list number of starts since fault code was set.
- The start counter (key counter) helps to determine if fault is intermittent. As an example, if DRB-II displays 0 STARTS SINCE ERS, this indicates zero engine starts since fault occurred, and fault code is a hard failure. If start counter (key counter) on DRB-II shows more than zero engine starts since fault last occurred, fault code is an intermittent failure.
- If more than one fault code exists, press the down arrow to display next fault code. All fault codes must be read before fault codes can be erased. Once fault codes are obtained, refer to appropriate NO START TEST 1A (NS-1A) or DRIVEABILITY TEST 1A (DR-1A) trouble shooting chart.
NOTE: When using trouble shooting charts for diagnosis, DO NOT skip any steps in chart, or incorrect diagnosis may result.
Dodge Caravan ES 1991 - CLEARING FAULT CODES
NOTE: It will be necessary to place DRB-II in the FUEL/IGN MENU to erase fault codes. This menu is obtained when retrieving fault codes. See DRB-II METHOD under RETRIEVING FAULT CODES .
- Once fault codes have been read and DRB-II is in FUEL/IGN MENU, press the down arrow. Display will read as follows: ERASE FAULTS, 1) DON'T ERASE, and 2) ERASE. Press the down arrow.
- Display will ask you if you are sure you want to erase fault codes. Press ENTER button to erase fault codes. DRB-II will display FAULTS ERASED message.
Dodge Caravan ES 1991 - OPERATING MODES * PLEASE READ THIS FIRST *
NOTE: Actuator, sensor, solenoid and switch tests available on DRB-II will vary depending on engine, transaxle and emission packages.
Dodge Caravan ES 1991 - STATE DISPLAY MODE
The SBEC can only recognize high and low states on switch circuits. SBEC cannot tell the difference between switch position versus an open or short circuit, or a defective switch.
If a change is noted, it is assumed entire switch circuit to the SBEC is operating correctly. The following information can be selected from the state display mode: module, sensor, inputs/outputs, monitoring of system, and custom display.
Dodge Caravan ES 1991 - Module Info
When module information is selected from STATE DISPLAY mode, information about the SBEC, such as, engine application, transmission application and identification number can be obtained. Information can be used to verify proper SBEC application.
Dodge Caravan ES 1991 - Sensor
When sensor information is selected from STATE DISPLAY mode, information is provided about engine operation through various sensors and engine controls depending on engine and model application. The following information may be displayed.
- Added Adaptive Fuel
- Adaptive Fuel Factor
- Air Idle Speed (AIS) Motor Position
- Barometric Pressure
- Battery Temperature
- Battery Voltage
- Charging System Goal
- Charge Temperature
- Charge Temperature Sensor Reading
- Coolant Temperature
- Coolant Temperature Sensor Reading
- Distributorless Ignition System (DIS) Status
- Engine Speed
- Fault No. 1 Key-On Info
- Fault No. 2 Key-On Info
- Fault No. 3 Key-On Info
- Knock Sensor Signal
- Manifold Absolute Pressure Sensor Vacuum Reading
- Manifold Absolute Pressure Sensor Voltage Reading
- Minimum Idle Speed
- Minimum Throttle Position Sensor Voltage
- Module Spark Advance
- Overall Knock Retard
- Oxygen Sensor State
- Oxygen Sensor Voltage
- Theft Alarm Status
- Throttle Body Temperature
- Throttle Opening
- Throttle Position Sensor Voltage
- Total Spark Advance
- Speed Control Status
- Speed Control Target
- Vehicle Speed
Dodge Caravan ES 1991 - Inputs/Outputs
When input/output information is selected from state display mode, information is provided about component operation through various lights, relays, solenoids and switches depending on engine and model application. The following information may be displayed.
- A/C Clutch Relay
- A/C Switch
- Air Switching Solenoid
- Auto Shutdown (ASD) Relay
- Brake Switch
- CHECK ENGINE Light
- Closed Throttle Switch
- EGR Solenoid
- Emission Maintenance Reminder (EMR) Light
- Idle Switch
- Lockup Solenoid
- Overdrive Override
- Overdrive Solenoid
- Park Neutral Switch (A/T Models)
- Part Throttle Unlock (PTU) A/T Only
- Purge Control Solenoid
- Radiator Fan Relay
- Shift Indicator Light
- Speed Control On/Off Switch
- Speed Control Resume
- Speed Control Setting
- Speed Control Vacuum Solenoid
- Speed Control Vent Solenoid
Dodge Caravan ES 1991 - Monitors
When monitor information is selected from STATE DISPLAY mode, information is provided about various systems or components as they are monitored depending on engine and model application. The following possible information may be displayed.
- Adaptive Memory
- Engine RPM
- Fuel Control
- Fuel Mileage
- Interrogator
- Knock Retard
- No Start
- Secondary Indicators
- Spark Advance
Dodge Caravan ES 1991 - Custom Display
When custom display is selected, information can be changed to what the technician wants to monitor.
Dodge Caravan ES 1991 - ACTUATOR TEST MODE
Actuator test mode is used to check operation of output circuits of devices the SBEC cannot recognize. The following, depending on engine and model application, can be activated in actuator test mode to ensure component operation: relays, solenoids and various components. The following are information or components that may be accessed through actuator test mode.
- A/C Clutch Relay
- Air Idle Speed (AIS) Motor
- Air Switch Solenoid
- Alternator Field
- ASD (Auto Shutdown) Relay
- ASD (Auto Shutdown) System
- CHECK ENGINE Light
- EGR Solenoid
- Emission Maintenance Reminder (EMR) Light
- Fuel Injector
- Ignition Coil
- Overdrive Solenoid
- Part Throttle Unlock (PTU) A/T Only
- Purge Solenoid
- Radiator Fan Relay
- Shift Indicator Light (M/T Only)
- Solenoid/Relays
- Speed Control Servo Solenoids
- Stop All Tests
- Tachometer Output
Dodge Caravan ES 1991 - ADJUSTMENTS MODE
In adjustments mode, fault codes can be erased and memory can be reset for the adaptive fuel, minimum TPS and all values. If SBEC is replaced, the Emission Maintenance Reminder (EMR) light can be reset, EMR light memory can be checked, and EMR mileage can be transferred.
Dodge Caravan ES 1991 - DRB-II PROBLEMS & ERROR MESSAGES BAD FRAMING
If message is displayed, replace cartridge with later version.
Dodge Caravan ES 1991 - BAD OP CODE
If message is displayed, replace cartridge with later version.
Dodge Caravan ES 1991 - BLANK MESSAGE
- Connect DRB-II to a different vehicle. If message screen is still blank, DRB-II or adapter cable are faulty. Substitute to determine faulty component. If message screen is not blank, DRB-II and adapter cable are functioning properly.
- Inspect diagnostic connector for proper wire placement, damaged terminals or pushed out pins. Repair as necessary. If connector is okay, check resistance between Black or Black/White wire of diagnostic connector and ground using an ohmmeter. See Fig. 1 .
- If resistance is less than 10 ohms, repair open circuit in Black or Black/White wire between diagnostic connector and 60-pin connector on the SBEC. See SBEC LOCATIONS table for component location.
Dodge Caravan ES 1991 SBEC LOCATIONS
Model Location Dakota Right Front Fender, Above Tire All Others Left Front Corner Of Engine Compartment
Dodge Caravan ES 1991 - CARTRIDGE ERROR
If message is displayed, replace DRB-II cartridge and proceed with diagnostics.
Dodge Caravan ES 1991 - COMMAND REJECTED
If message is displayed, replace cartridge with later version.
Dodge Caravan ES 1991 - HIGH BATTERY
If message is displayed, connect DRB-II to a different vehicle. If message still exists, DRB-II or adapter cable are faulty. Substitute to determine faulty component. If message is not displayed, DRB-II and adapter cable are functioning properly. Repair charging system.
Dodge Caravan ES 1991 - KEYPAD TEST FAILURE
Ensure ignition is off. DO NOT touch keypad on DRB-II. Turn ignition on. If DRB-II displays KEYPAD TEST FAILURE, replace DRB-II. If KEYPAD TEST FAILURE message is not displayed, proceed with diagnostics.
Dodge Caravan ES 1991 - LOW BATTERY
If message is displayed, connect DRB-II to a different vehicle. If message still exists, DRB-II or adapter cable are faulty. Substitute to determine faulty component. If message is not displayed, DRB-II and adapter cable are functioning properly. Repair charging system.
Dodge Caravan ES 1991 - NO RESPONSE
NOTE: No response may be caused by one of the following: DRB-II is connected to wrong diagnostic connector, ignition is off, defective adapter cable, cartridge or DRB-II, defective SBEC, connector or wiring.
- Ensure DRB-II is connected to proper diagnostic connector. See Fig. 2 -5. Ensure ignition is turned on and all wiring connections are secure.
- Turn ignition off. Disconnect DRB-II from diagnostic connector. Disconnect 60-pin connector from SBEC. See SBEC LOCATIONS table for component location. Using ohmmeter, check resistance between Pink wire terminal on diagnostic connector and pin No. 25 (Pink wire) on 60-pin connector. See Fig. 1 and Fig. 6 .
- If resistance is greater than 10 ohms, repair open circuit in Pink wire between diagnostic connector and 60-pin connector. If resistance is not greater than 10 ohms, check resistance between Light Green wire terminal on diagnostic connector and pin No. 45 (Light Green wire) on 60-pin connector.
- If resistance is greater than 10 ohms, repair open circuit in Light Green wire between diagnostic connector and 60-pin connector. If resistance is not greater than 10 ohms, ensure DRB-II and adapter cable are okay.
- If all above are okay and a no-start condition exists, proceed to appropriate no-start test NS-12A. Checking System Power, Engine Controller, MAP Sensor
Dodge Caravan ES 1991 - RAM TEST FAILURE
If message is displayed, replace DRB-II and proceed with diagnostics.
Dodge Caravan ES 1991 - EMISSION MAINTENANCE REMINDER (EMR) EMR LIGHT RESET PROCEDURE
- The EMR light serves as the vehicle emissions control system service reminder. EMR light is not an emissions warning system; it is only a reminder to perform emissions servicing.
- The EMR light will illuminate at 60,000, 82,500 and 120,000-mile intervals. Service specified components at designated interval. See EMR LIGHT COMPONENT SERVICE INTERVAL table.
Dodge Caravan ES 1991 EMR LIGHT COMPONENT SERVICE INTERVAL
Interval Component To Be Serviced 60,000 Miles Replace EGR Valve & Tube (If Equipped) Clean EGR Passage, Replace PCV Valve 82,500 Miles Replace Oxygen Sensor 120,000 Miles Replace EGR Valve & Tube (If Equipped) Clean EGR Passage, Replace PCV Valve - Once components have been serviced, EMR light can be reset. It will be necessary to place DRB-II in the FUEL/IGN MENU to reset EMR light. This menu is obtained when retrieving fault codes. See DRB-II METHOD under RETRIEVING FAULT CODES under SELF-DIAGNOSTIC SYSTEM.
- Once in FUEL/IGN MENU, press the down arrow to select No. 5) ADJUSTMENTS. Display will read as follows: ADJUSTMENTS, 1) ERASE FAULTS, 2) RESET MEMORY, 3) RESET EMR LIGHT, and 4) EMR MEMORY CHECK. Press the down arrow to select No. 3) RESET EMR LIGHT.
- Display will ask if you are sure you want to reset EMR light. Press ENTER button to reset EMR light.
Dodge Caravan ES 1991 - EMR MILEAGE TRANSFER
- When SBEC is replaced, vehicle mileage from odometer must be copied to the replacement SBEC memory. Transfer of vehicle mileage will enable replacement SBEC to operate EMR light properly.
- It will be necessary to place DRB-II in the FUEL/IGN MENU to reset EMR light. This menu is obtained when retrieving fault codes. See DRB-II METHOD under RETRIEVING FAULT CODES under SELF-DIAGNOSTIC SYSTEM.
- Once in FUEL/IGN MENU, press the down arrow to select No. 5) ADJUSTMENTS. Display will read as follows: ADJUSTMENTS, 1) ERASE FAULTS, 2) RESET MEMORY, 3) RESET EMR LIGHT, and 4) EMR MEMORY CHECK. Press the down arrow to select No. 4) EMR MEMORY CHECK.
- Display will ask if you are sure you want to check EMR memory. Press ENTER button to continue. Display will read as follows: EMR MEMORY TEST, and WRITE TEST [------]. Display will now ask if instrument panel mileage is between a specified amount.
- Press YES or NO button. If YES button is pressed, EMR memory check is completed. If NO button is pressed, enter mileage shown on the odometer. Press ENTER button to complete mileage transfer.
Dodge Caravan ES 1991 - SBEC LOCATION
Dodge Caravan ES 1991 SBEC LOCATIONS
Model Location Dakota Right Front Fender, Above Tire All Others Left Front Corner Of Engine Compartment
Dodge Caravan ES 1991 - SUMMARY
If no hard fault codes (or only pass codes) are present, driveability symptoms exist, or intermittent codes exist, proceed to TESTS W/O CODES article for diagnosis by symptom (i.e. ROUGH IDLE, NO START, etc.), or intermittent diagnostic procedures.
Fig. 6: Dodge Caravan ES 1991 - Component Locations - Identifying SBEC 60-Pin Connector Terminals
Dodge Caravan ES 1991 - FAULT CODE CHARTS * PLEASE READ THIS FIRST *
NOTE: Fault code charts may contain references to body types not covered in this article.
Dodge Caravan ES 1991 - FAULT CODES
Dodge Caravan ES 1991 FAULT CODES (1)
Code Display On DRB-II Fault Condition 11 NO REFERENCE SIGNAL DURING CRANKING No distributor reference signal detected during cranking. 13 (2) NO CHANGE IN MAP FROM START TO RUN No difference is recognized between engine MAP reading and barometric pressure reading at start-up OR SLOW CHANGE IN IDLE MAP SIGNAL No difference in MAP sensor signal is detected. 14 (2) MAP VOLTAGE TOO LOW MAP sensor input less than minimum acceptable voltage. MAP VOLTAGE TOO HIGH MAP sensor input greater than maximum acceptable voltage. 15 (3) NO VEHICLE SPEED SIGNAL No vehicle speed sensor signal detected. 17 ENGINE IS COLD TOO LONG Coolant temperature less than normal operating temperature. 21 (3) O2 SIGNAL STAYS AT CENTER No rich or lean signal is detected from O2 sensor input. O2 SIGNAL SHORTED TO VOLTAGE Oxygen sensor input voltage greater than normal operating range. 22 (2) COOLANT SENSOR VOLTAGE TOO LOW Coolant temperature sensor input is low. COOLANT SENSOR VOLTAGE TOO HIGH Coolant temperature sensor input is high. 23 (4) THROTTLE BODY TEMP VOLTAGE LOW Throttle body temperature sensor input voltage is low. THROTTLE BODY TEMP VOLTAGE HIGH Throttle body temperature sensor input voltage is high. (2) CHARGE TEMPERATURE SENSOR VOLTAGE HIGH OR LOW Charge temperature sensor input voltage is less than or greater than acceptable voltage. 24 (2) TPS VOLTAGE LOW TPS sensor output voltage is less than acceptable voltage. TPS VOLTAGE HIGH TPS sensor output is greater than maximum acceptable voltage. 25 (3) AUTOMATIC IDLE SPEED MOTOR CIRCUITS Shorted condition detected in one or more AIS actuator circuits. 26(2) INJ 1 PEAK VOLTAGE NOT OBTAINED High resistance in No. 1 injector circuit. 26 INJ 2 PEAK VOLTAGE NOT OBTAINED High resistance in No. 2 injector circuit. 26 INJ 3 PEAK VOLTAGE NOT OBTAINED High resistance in No. 3 injector circuit. 27 INJ 1 CONTROL CIRCUIT Injector output driver does not respond correctly to control signal. 27 INJ 2 CONTROL CIRCUIT Injector output driver does not respond correctly to control signal. 27 INJ 3 CONTROL CIRCUIT Injector output driver does not respond correctly to control signal. 31 (3) PURGE SOLENOID CIRCUIT Open or shorted condition detected in purge solenoid circuit. 32 (3) EGR SOLENOID CIRCUIT Open or shorted condition detected in EGR solenoid circuit. EGR SYSTEM FAILURE Controller did not detect required air/fuel mixture change during diagnostic test (CA only). 33 A/C CLUTCH RELAY CIRCUIT Open or shorted condition detected in A/C clutch relay circuit. 34 SPEED CONTROL SOLENOID CIRCUITS Open or shorted condition detected in speed control vacuum or vent solenoid circuits. 35 (4) RADIATOR FAN RELAY CIRCUIT Open or shorted circuit in radiator fan relay circuit. 36 AIR SWITCHING SOLENOID CIRCUIT Open or shorted condition detected in air switching solenoid circuit. 37 (5) TORQUE CONVERTER LOCK-UP SOLENOID CIRCUIT Open or shorted condition detected in torque converter lockup solenoid circuit (A/T only). 41 (2) ALTERNATOR FIELD NOT SWITCHING Alternator field not switching properly. 42 ASD RELAY CONTROL CIRCUIT Open or shorted Condition detected in ASD relay circuit. NO ASD RELAY VOLTAGE SENSE AT SBEC No ASD voltage sensed at controller. 43 (3) IGNITION COIL NO. 1 PRIMARY CIRCUIT Peak primary current not obtained with maximum dwell. 43 IGNITION COIL NO. 2 PRIMARY CIRCUIT Peak primary current not obtained with maximum dwell. 43 IGNITION COIL NO. 3 PRIMARY CIRCUIT Peak primary current not obtained with maximum dwell. 45 OVERDRIVE SOLENOID CIRCUIT Open or shorted condition detected in overdrive solenoid circuit. 46 (2) CHARGING SYSTEM VOLTAGE TOO HIGH Charging system voltage is more than acceptable voltage. 47 (2) CHARGING SYSTEM VOLTAGE TOO LOW Charging system voltage is less than acceptable voltage. 51 (3) O2 SIGNAL STAYS BELOW CENTER (LEAN) O2 sensor signal stays lean. OR ADDITIVE ADAPTIVE MEMORY AT RICH LIMIT Additive adaptive memory at rich limit. 52 (3) O2 SIGNAL STAYS ABOVE CENTER (RICH) O2 sensor signal stays rich. OR ADDITIVE ADAPTIVE MEMORY AT LEAN LIMIT Additive adaptive memory at lean limit 53 INTERNAL CONTROLLER FAILURE Internal failure in controller. 54 (2) NO SYNC PICK-UP SIGNAL No fuel sync signal detected during engine rotation. 55 N/A Completion of fault code display (CHECK ENGINE light). 62 CONTROLLER FAILURE EMR MILES ** NOT STORED Controller failure, EMR miles not stored. 63 CONTROLLER FAILURE EEPROM WRITE DENIED Controller failure, EEPROM write denied.
(1) Fault code application will vary with model and engine application. Not all fault codes are used on all models.
(2) CHECK ENGINE light will be on.
(3) CHECK ENGINE light will be on (California models only).
(4) Used on 2.5L (Dakota)
(5) On some models, this may be referred to as part throttle unlock solenoid.
Dodge Caravan ES 1991 - TROUBLE SHOOTING CHARTS
NOTE: The following trouble shooting charts and illustrations are courtesy of Chrysler Motors.
Dodge Caravan ES 1991 - NO START DIAGNOSTIC FLOW CHARTS: NS-1A TO NS-17A
NOTE: The following trouble shooting charts and illustrations are courtesy of Chrysler Motors.
Dodge Caravan ES 1991 - NS-1A: CHECKING FOR IGNITION SPARK & POWER FEED TO COIL
Dodge Caravan ES 1991 - NS-2A: CHECKING FOR FUEL SPRAY & FAULT MESSAGES WITH DRB-II
Dodge Caravan ES 1991 - NS-3A: CHECKING FOR INJECTOR FAULTS, POWER TO SBEC, MAP SENSOR & THEFT STATUS
Dodge Caravan ES 1991 - NS-4A: CHECKING FOR FUEL PRESSURE, TPS & POWER FEED TO INJECTORS
Shadow and Sundance Convertible models are manufactured with either early or late design fuel, ignition and emission systems. Late design vehicles use an epoxy ignition coil, mounted on thermostat housing, and a high pressure fuel system requiring quick-connect fuel fittings. Early design vehicles use an oil-filled ignition coil, mounted on right inner fender, and a low pressure fuel system using hoses and clamps.
Dodge Caravan ES 1991 - NS-5A: CHECKING FOR WET PLUGS, MAP SENSOR & IGNITION TIMING
Dodge Caravan ES 1991 - NS-5B: CHECKING VALVE GEAR
Fig. 22: Dodge Caravan ES 1991 - Component Locations - Test NS-5B: Valve Gear
Dodge Caravan ES 1991 - NS-6A: CHECKING FUEL FILTER, FUEL PUMP, PRESSURE REGULATOR & POWER TO FUEL PUMP
Dodge Caravan ES 1991 - NS-6B: CHECKING FUEL FILTER, FUEL PUMP, PRESSURE REGULATOR & POWER TO FUEL PUMP
Dodge Caravan ES 1991 - NS-7A: CHECKING FOR FLOODING FUEL INJECTOR
Fig. 27: Dodge Caravan ES 1991 - Component Locations - Test NS-7A Ckt Diag: Flooding Fuel Injector
Fig. 28: Dodge Caravan ES 1991 - Component Locations - Test NS-7A: (1 of 3) Flooding Fuel Injector
Fig. 29: Dodge Caravan ES 1991 - Component Locations - Test NS-7A: (2 of 3) Flooding Fuel Injector
Fig. 30: Dodge Caravan ES 1991 - Component Locations - Test NS-7A: (3 of 3) Flooding Fuel Injector
Dodge Caravan ES 1991 - NS-7B: CHECKING FOR FLOODING FUEL INJECTOR, KINKED FUEL LINES & PRESSURE REGULATOR. OPERATION
Fig. 31: Dodge Caravan ES 1991 - Component Locations - Test NS-7B: (1 of 2) Flooding Fuel Injector
Fig. 32: Dodge Caravan ES 1991 - Component Locations - Test NS-7B: (2 of 2) Flooding Fuel Injector
Dodge Caravan ES 1991 - NS-8A: CHECKING FOR HIGH FUEL PRESSURE AT PRESSURE REGULATOR & FUEL TANK
Dodge Caravan ES 1991 - NS-9A: CHECKING FOR DEFECTIVE COIL OR CONTROL CIRCUITRY
Dodge Caravan ES 1991 - NS-10A: CHECKING INJECTOR, CONTROL CIRCUIT & SBEC
Dodge Caravan ES 1991 - NS-10B: CHECKING INJECTOR, CONTROL CIRCUIT & SBEC
Dodge Caravan ES 1991 - NS-11A: CHECKING DRB-II & SYSTEM FAULTS
Fig. 44: Dodge Caravan ES 1991 - Component Locations - Test NS-11A: DRB-II & System Faults
Dodge Caravan ES 1991 - NS-12A: CHECKING FOR SYSTEM POWER, OPERATION OF MAP SENSOR & SBEC
Dodge Caravan ES 1991 - NS-12B: CHECKING FOR SYSTEM POWER & OPERATION OF MAP SENSOR & SBEC
Dodge Caravan ES 1991 - NS-13A: NO IGNITION REFERENCE SIGNAL DURING CRANKING (DTC 11)
Dodge Caravan ES 1991 - NS-13B: NO IGNITION REFERENCE SIGNAL DURING CRANKING
Dodge Caravan ES 1991 - NS-13C: NO IGNITION REFERENCE SIGNAL DURING CRANKING
Dodge Caravan ES 1991 - NS-14A: ASD RELAY CIRCUIT (DTC 42)
Fig. 60: Dodge Caravan ES 1991 - Component Locations - Test NS-14A: Ckt Diag. ASD Relay Circuit
Fig. 61: Dodge Caravan ES 1991 - Component Locations - Test NS-14A: (1 of 2) ASD Relay Circuit
Fig. 62: Dodge Caravan ES 1991 - Component Locations - Test NS-14A: (2 of 2) ASD Relay Circuit
Dodge Caravan ES 1991 - NS-15A: CHECKING ASD RELAY, POWER FEED TO FUEL PUMP, OXYGEN SENSOR & INJECTORS
Dodge Caravan ES 1991 - NS-16A: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 68: Dodge Caravan ES 1991 - Component Locations - Test NS-16A: Idle Speed Motor Operation
Dodge Caravan ES 1991 - NS-16B: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 69: Dodge Caravan ES 1991 - Component Locations - Test NS-16B: Idle Speed Motor Operation
Dodge Caravan ES 1991 - NS-16C: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 70: Dodge Caravan ES 1991 - Component Locations - Test NS-16C: Idle Speed Motor Operation
Dodge Caravan ES 1991 - NS-16D: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 71: Dodge Caravan ES 1991 - Component Locations - Test NS-16D: Idle Speed Motor Operation
Dodge Caravan ES 1991 - NS-16E: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 72: Dodge Caravan ES 1991 - Component Locations - Test NS-16E: Idle Speed Motor Operation
Dodge Caravan ES 1991 - NS-17A: PERFORMING NO FAULT CODE MECHANICAL TEST
At this point in the start-and-stall test procedure, if it is determined that all engine control systems are operating as designed and are not the cause of a no start-and-stall problem, the following additional items should be checked as possible causes:
- Check if any TECHNICAL SERVICE BULLETINS (TSBs) apply to vehicle.
- Check engine vacuum.
- Check engine compression.
- Check for exhaust system restriction.
- Check camshaft and crankshaft sprockets.
- Check valve timing.
- Check torque converter stall speed.
- Check secondary ignition circuit for abnormal scope pattern.
- Check for fuel contamination.
- Ensure PCV system is functioning properly.
Dodge Caravan ES 1991 - DRIVEABILITY DIAGNOSTIC FLOW CHARTS DR-1A TO DR-45A
NOTE: The following trouble shooting charts and illustrations are courtesy of Chrysler Motors.
Dodge Caravan ES 1991 - DR-1A: CHECKING SYSTEM FOR FAULTS
NOTE: Battery must be fully charged and at rated capacity before performing any driveability test procedure. If vehicle starts and stalls repeatedly, perform test NS-3A: CHECKING FOR INJECTOR FAULTS, POWER TO ENGINE CONTROLLER, MAP SENSOR & THEFT ALARM STATUS.
- Connect DRB-II to engine diagnostic connector. Read fault messages. If DRB-II displays fault messages, go to DR-1B: DRB-II FAULT MESSAGES. Go to step 9) if DRB-II displays ENGINE COLD TOO LONG. If DRB-II displays INTERNAL CONTROLLER FAILURE, go to step 8). If DRB-II displays NO FAULTS, go to next step.
- If NO FAULTS message appears on DRB-II display, start engine. Allow engine to reach normal operating temperature. Set engine speed manually (DO NOT use DRB-II to set speed) to 2000 RPM for about 10 seconds. Return engine to idle.
- If vehicle is not equipped with A/C, go to step 5). If vehicle is equipped with A/C, put A/C fan on low speed. Turn A/C on. If engine stalls when A/C is turned on, turn ignition switch off.
- Disconnect engine controller connector. Inspect engine controller connector for corroded or loose terminals. Repair as required. Turn ignition switch on. Put DRB-II in voltmeter mode.
- Probe engine controller connector DB (Dark/Blue) wire at cavity No. 9. If voltage is less than 10 volts, repair DB wire. If voltage is more than 10 volts, replace engine controller. Perform test VER-2: VERIFICATION PROCEDURE 2.
- If vehicle is equipped with A/T, apply brakes and shift through all gears. Return shift lever to Park. Read fault messages displayed on DRB-II.
- If DRB-II still shows NO FAULTS, check TECHNICAL SERVICE BULLETINS for any pertinent information relating to driveability problems. If a TSB exists, perform corrective action. If driveability problem continues after performing TSB procedure or if no TSB information is found, perform test DR-30A: CHECKING SECONDARY IGNITION & TIMING.
- If INTERNAL CONTROLLER FAILURE message appears on DRB-II display, replace engine controller. Perform test VER-2: VERIFICATION PROCEDURE 2.
- If ENGINE COLD TOO LONG message appears on DRB-II display, check engine cooling system. Repair as required. Perform test VER-3: VERIFICATION PROCEDURE 3.
Dodge Caravan ES 1991 - DR-1B: DRB-II FAULT MESSAGES
Using the DRB-II FAULT MESSAGES table, select the fault message and corresponding test. Correct all hard fault messages before proceeding to intermittent fault message.
Dodge Caravan ES 1991 DRB-II FAULT MESSAGES
DRB Message Hard Fault (1) Intermittent Fault (2) A/C Clutch Relay Circuit (3) DR-19A DR-42A A/C Clutch Relay Circuit (4) DR-20A DR-42A A/C Clutch Relay Circuit (5) DR-21A DR-42A A/C Clutch Relay Circuit (6) DR-22A DR-42A A/C Clutch Relay Circuit (7) DR-23A DR-42A Automatic Idle Speed Motor Circuits DR-15A DR-44A Controller Failure EEPROM Write Denied DR-29A DR-29A Controller Failure EMR Mileage Not Stored DR-29A DR-29A Coolant Sensor Voltage Too High DR-9A DR-43A Coolant Sensor Voltage Too Low DR-10A DR-43A EGR Solenoid Circuit DR-17A DR-42A EGR System Failure DR-18A DR-42A Injector No. 1 Control Circuit DR-45A DR-45A Injector No. 1 Current Peak Not Reached DR-45A DR-45A MAP Voltage Too High DR-5A DR-43A MAP Voltage Too Low DR-4A DR-43A No Change In MAP From Start To Run DR-3A DR-43B No Vehicle Speed Signal DR-6A DR-6A O2 Signal Shorted To Voltage DR-8A DR-43A O2 Signal Stays At Center DR-7A DR-43A Purge Solenoid Circuit DR-16A DR-42A Radiator Fan Relay Circuit (8) DR-24A DR-42A Radiator Fan Relay Circuit (4) DR-25A DR-42A Radiator Fan Relay Circuit (5) DR-26A DR-42A Radiator Fan Relay Circuit (6) DR-27A DR-42A Slow Change In Idle MAP Signal DR-2A DR-43B Throttle Body Temperature High DR-11A DR-43A Throttle Body Temperature Low DR-12A DR-43A Throttle Position Sensor Voltage High DR-13A DR-43A Throttle Position Sensor Voltage Low DR-14A DR-43A Torque Converter Lock-Up Solenoid DR-28A DR-42A
(1) Key counter is "0".
(2) Key counter is more than "0".
(3) AA & AP bodies.
(4) AC bodies.
(5) AG & AJ bodies.
(6) AN bodies.
(7) AS bodies.
(8) AP & AS bodies.
Dodge Caravan ES 1991 - DR-2A: SLOW CHANGE IN IDLE MAP SIGNAL (DTC 13)
Dodge Caravan ES 1991 - DR-3A: NO CHANGE IN MAP FROM START TO RUN (DTC 13)
Dodge Caravan ES 1991 - DR-4A: MAP VOLTAGE TOO LOW (DTC 14)
Fig. 78: Dodge Caravan ES 1991 - Component Locations - Test DR-4A, Code 14: MAP Voltage Too Low
Dodge Caravan ES 1991 - DR-5A: MAP VOLTAGE TOO HIGH (DTC 14)
Dodge Caravan ES 1991 - DR-6A: NO VEHICLE SPEED SIGNAL (DTC 15)
Dodge Caravan ES 1991 - DR-7A: O2 SIGNAL STAYS AT CENTER (DTC 21)
Dodge Caravan ES 1991 - DR-8A: O2 SIGNAL SHORTED TO VOLTAGE (DTC 21)
Dodge Caravan ES 1991 - DR-9A: COOLANT SENSOR VOLTAGE TOO HIGH (DTC 22)
Dodge Caravan ES 1991 - DR-10A: COOLANT SENSOR VOLTAGE TOO LOW (DTC 22)
Dodge Caravan ES 1991 - DR-11A: THROTTLE BODY TEMPERATURE HIGH (DTC 23)
Dodge Caravan ES 1991 - DR-12A: THROTTLE BODY TEMPERATURE LOW (DTC 23)
Fig. 101: Dodge Caravan ES 1991 - Component Locations - Test DR-12A, Code 23: Throttle Body Temp Low
Dodge Caravan ES 1991 - DR-13A: THROTTLE POSITION SENSOR VOLTAGE HIGH (DTC 24)
Dodge Caravan ES 1991 - DR-14A: THROTTLE POSITION SENSOR VOLTAGE LOW (DTC 24)
Fig. 106: Dodge Caravan ES 1991 - Component Locations - Test DR-14A, Code 24: TPS Voltage Low
Dodge Caravan ES 1991 - DR-15A: AUTOMATIC IDLE SPEED MOTOR CIRCUITS (DTC 25)
Dodge Caravan ES 1991 - DR-16A: PURGE SOLENOID CIRCUIT (DTC 31)
Dodge Caravan ES 1991 - DR-17A: EGR SOLENOID CIRCUIT (DTC 32)
Dodge Caravan ES 1991 - DR-18A: EGR SYSTEM FAILURE (DTC 32)
Dodge Caravan ES 1991 - DR-18B: EGR SYSTEM FAILURE
Dodge Caravan ES 1991 - DR-18C: EGR SYSTEM FAILURE
Fig. 130: Dodge Caravan ES 1991 - Component Locations - Test DR-18C, Code 32: EGR System Failure
Dodge Caravan ES 1991 - DR-19A: A/C CLUTCH RELAY CIRCUIT (DTC 33)
Dodge Caravan ES 1991 - DR-20A: A/C CLUTCH RELAY CIRCUIT (DTC 33)
Dodge Caravan ES 1991 - DR-21A: A/C CLUTCH RELAY CIRCUIT (DTC 33)
Dodge Caravan ES 1991 - DR-22A: A/C CLUTCH RELAY CIRCUIT (DTC 33)
Dodge Caravan ES 1991 - DR-23A: A/C CLUTCH RELAY CIRCUIT (DTC 33)
Dodge Caravan ES 1991 - DR-24A: RADIATOR FAN RELAY CIRCUIT (DTC 35)
Dodge Caravan ES 1991 - DR-25A: RADIATOR FAN RELAY CIRCUIT (DTC 35)
Dodge Caravan ES 1991 - DR-26A: RADIATOR FAN RELAY CIRCUIT (DTC 35)
Dodge Caravan ES 1991 - DR-27A: RADIATOR FAN RELAY CIRCUIT (DTC 35)
Dodge Caravan ES 1991 - DR-28A: TORQUE CONVERTER LOCK-UP SOLENOID (DTC 37)
Dodge Caravan ES 1991 - DR-29A: SBEC FAILURE EMR MILEAGE NOT STORED & EEPROM WRITE DENIED (DTC 63)
Dodge Caravan ES 1991 - DR-30A: CHECKING SECONDARY IGNITION & TIMING
Dodge Caravan ES 1991 - DR-31A: CHECKING FUEL PRESSURE
Fig. 171: Dodge Caravan ES 1991 - Component Locations - Test DR-31A: (1 of 2) Fuel Pressure
Fig. 172: Dodge Caravan ES 1991 - Component Locations - Test DR-31A: (2 of 2) Fuel Pressure
Dodge Caravan ES 1991 - DR-31B: CHECKING FUEL PRESSURE
Fig. 173: Dodge Caravan ES 1991 - Component Locations - Test DR-31B: (1 of 2) Fuel Pressure
Fig. 174: Dodge Caravan ES 1991 - Component Locations - Test DR-31B: (2 of 2) Fuel Pressure
Dodge Caravan ES 1991 - DR-32A: CHECKING COOLANT & TPS SENSOR CALIBRATION
Dodge Caravan ES 1991 - DR-33A: CHECKING MAP SENSOR CALIBRATION
Fig. 177: Dodge Caravan ES 1991 - Component Locations - Test DR-33A: (1 of 2) MAP Sensor Calibration
Fig. 178: Dodge Caravan ES 1991 - Component Locations - Test DR-33A: (2 of 2) MAP Sensor Calibration
Dodge Caravan ES 1991 - DR-34A: CHECKING OXYGEN SENSOR SWITCHING
Fig. 179: Dodge Caravan ES 1991 - Component Locations - Test DR-34A: Oxygen Sensor Switching
Dodge Caravan ES 1991 - DR-34B: CHECKING OXYGEN SENSOR SWITCHING
Dodge Caravan ES 1991 - DR-35A: CHECKING IDLE SPEED MOTOR OPERATION
Dodge Caravan ES 1991 - DR-35C: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 185: Dodge Caravan ES 1991 - Component Locations - Test DR-35B: Idle Speed Motor Operation
Fig. 186: Dodge Caravan ES 1991 - Component Locations - Test DR-35C: Idle Speed Motor Operation
Dodge Caravan ES 1991 - DR-35D: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 187: Dodge Caravan ES 1991 - Component Locations - Test DR-35D: Idle Speed Motor Operation
Dodge Caravan ES 1991 - DR-35E: CHECKING IDLE SPEED MOTOR OPERATION
Fig. 188: Dodge Caravan ES 1991 - Component Locations - Test DR-35E: Idle Speed Motor Operation
Dodge Caravan ES 1991 - DR-36A: CHECKING PARK/NEUTRAL SWITCH OPERATION
Dodge Caravan ES 1991 - DR-37A: CHECKING SBEC GROUNDS & POWER CIRCUITS
Dodge Caravan ES 1991 - DR-38A: CHECKING EGR OPERATION FEDERAL EMISSIONS
Dodge Caravan ES 1991 - DR-38B: CHECKING EGR OPERATION FEDERAL EMISSIONS
Fig. 197: Dodge Caravan ES 1991 - Component Locations - Test DR-38B: EGR Operation Federal Emissions
Dodge Caravan ES 1991 - DR-38C: CHECKING EGR OPERATION FEDERAL EMISSIONS
Dodge Caravan ES 1991 - DR-39A: CHECKING ENGINE VACUUM
Fig. 203: Dodge Caravan ES 1991 - Component Locations - Test DR-39A: Ckt Diag. Engine Vacuum
Fig. 204: Dodge Caravan ES 1991 - Component Locations - Test DR-40A: (1 of 2) Engine Vacuum
Fig. 205: Dodge Caravan ES 1991 - Component Locations - Test DR-40A: (2 of 2) Engine Vacuum
Dodge Caravan ES 1991 - DR-41A: PERFORMING NO FAULT CODE MECHANICAL TEST
At this point in the driveability test procedure, if it is determined that all engine control systems are operating as designed and are not the cause of driveability problem, check the following additional items for possible causes:
- Check valve timing.
- Check torque converter stall speed.
- Check engine compression.
- Check camshaft and crankshaft sprockets.
- Check for internal power brake booster vacuum leaks.
- Check for fuel contamination.
- Check for exhaust system restriction.
- Ensure injectors are not plugged or restricted.
- Ensure injector control wire is connected to correct injector.
- Ensure engine vacuum is at least 13 in. Hg.
- Ensure PCV system is functioning properly.
Dodge Caravan ES 1991 - DR-42A: INTERMITTENT TEST FOR SOLENOIDS & RELAYS
Dodge Caravan ES 1991 - DR-43A: INTERMITTENT TEST FOR VOLTAGE SENSOR
Fig. 207: Dodge Caravan ES 1991 - Component Locations - Test DR-43A: Intermittent Voltage Sensor
Dodge Caravan ES 1991 - DR-43B: INTERMITTENT TEST FOR MAP SENSOR SIGNAL CHANGE
Dodge Caravan ES 1991 - DR-44A: INTERMITTENT TEST FOR IDLE MOTOR CIRCUITS
Dodge Caravan ES 1991 - DR-45A: INTERMITTENT TEST FOR INJECTOR CIRCUITS
Dodge Caravan ES 1991 - VERIFICATION FLOW CHARTS: VER-1 TO VER-3 VER-1: VERIFICATION PROCEDURE 1
- Inspect vehicle to ensure all components are connected. Reassemble and reconnect components as necessary. Attempt to start engine. If engine does not start, return to test NS-1A: CHECKING FOR IGNITION SPARK & POWER FEED TO COIL.
- If engine starts and engine controller has been changed, go to next step. If engine starts and engine controller has not been changed, connect DRB-II to engine diagnostic connector and erase faults. Repair is now complete.
- If vehicle is equipped with factory theft alarm system, start engine about 20 times to activate theft alarm system. If vehicle is an AS or AN body, write EMR mileage into the new engine controller. Repair is now complete.
Dodge Caravan ES 1991 - VER-2: VERIFICATION PROCEDURE 2
- If test VER-3: VERIFICATION PROCEDURE 3 has been performed previously, perform test VER-3 again. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary.
- If another fault exists that has not been corrected, return to DR-1B: DRB-II FAULT MESSAGES and follow path specified by other fault. If engine controller has been replaced and vehicle is equipped with factory theft alarm system, start engine about 20 times to activate theft alarm system. If vehicle is an AS or AN body, write EMR mileage into new engine controller.
- Connect DRB-II to engine diagnostic connector and erase faults. Ensure no other faults are present. To ensure no other faults are present, start engine. Allow engine to reach normal operating temperature. Increase engine speed to 2000 RPM for about 10 seconds. Return engine to idle.
- If vehicle is equipped with A/T, apply brakes and cycle through all transmission gear positions. Place gear selector in Park. If vehicle is equipped with A/C, turn A/C on. Set blower speed to LOW.
- Turn engine off. Start engine. Allow engine to idle for about 2 minutes. Turn engine off. Using DRB-II, check for fault messages. If NO FAULT message appears on DRB-II display, test is complete.
- If repaired fault resets or another fault sets, check TECHNICAL SERVICE BULLETINS for any pertinent information relating to problem. If a TSB exists, perform corrective action. If another fault sets, return to DR-1B: DRB-II FAULT MESSAGES.
Dodge Caravan ES 1991 - VER-3: VERIFICATION PROCEDURE 3
- Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If another fault is present that has not been corrected, return to DR-1B: DRB-II FAULT MESSAGES and follow path specified by other fault.
- If engine controller has been changed and vehicle is equipped with factory theft alarm system, start engine about 20 times to activate theft alarm system. If vehicle is an AS or AN body, write EMR mileage into new engine controller.
- Connect DRB-II to engine diagnostic connector. Erase fault messages. Disconnect DRB-II. Ensure no other fault messages are present. To ensure no other fault messages are present, start engine. If vehicle is equipped with A/C, turn A/C on. Set blower speed to LOW.
- Drive vehicle for about 5 minutes. During this time, attain a speed above 40 MPH or more. Ensure transmission shifts through all gears. Upon completion of road test, turn engine off.
- Start engine. Allow engine to idle for about 2 minutes. Turn engine off. Connect DRB-II to engine diagnostic connector. Using DRB-II, check for fault messages. If no fault messages are present, test is complete.
- If repaired fault message resets or another fault message sets, check TECHNICAL SERVICE BULLETINS for any pertinent information relating to driveability problems. If a TSB exists, perform corrective action. If another fault sets, return to DR-1B: DRB-II FAULT MESSAGES.