2005 Dodge Neon Service & Repair Manual

1.0 INTRODUCTION .........................................................1 1.1 SYSTEM COVERAGE ...............................................1 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1 2.0 IDENTIFICATION OF SYSTEM .............................................1 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1 3.1 GENERAL DESCRIPTION ............................................1 3.2 FUNCTION OPERATION .............................................1 3.2.1 FUEL CONTROL .............................................1 3.2.2 ON-BOARD DIAGNOSTICS ....................................2 3.2.3 OTHER CONTROLS ..........................................4 3.2.4 PCM OPERATING MODES ....................................4 3.2.5 NON-MONITORED CIRCUITS ..................................5 3.2.6 Sentry Key Immobilizer System (SKIS) Overview ...................5 3.2.7 SKIS Operation ..............................................6 3.3 DIAGNOSTIC TROUBLE CODES ......................................6 3.3.1 HARD CODE ................................................6 3.3.2 INTERMITTENT CODE ........................................6 3.3.3 Distance Since MI Set .........................................7 3.3.4 HANDLING NO TROUBLE CODE PROBLEMS ....................7 3.4 USING THE DRBIII .................................................8 3.5 DRBIII ERROR MESSAGES AND BLANK SCREEN ......................8 3.5.1 DRBIII DOES NOT POWER UP................................9 3.5.2 DISPLAY IS NOT VISIBLE .....................................9 4.0 DISCLAIMERS, SAFETY, WARNINGS .......................................9 4.1 DISCLAIMERS......................................................9 4.2 SAFETY ...........................................................9 4.2.1 TECHNICIAN SAFETY INFORMATION ...........................9 4.2.2 VEHICLE PREPARATION FOR TESTING .........................9 4.2.3 SERVICING SUB-ASSEMBLIES ................................9 4.2.4 DRBIII SAFETY INFORMATION...............................10 4.3 WARNINGS AND CAUTIONS ........................................10 4.3.1 ROAD TEST WARNINGS .....................................10 4.3.2 VEHICLE DAMAGE CAUTIONS ...............................10 5.0 REQUIRED TOOLS AND EQUIPMENT .....................................10 6.0 GLOSSARY OF TERMS ..................................................11 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................13 CHARGING P0622-GENERATOR FIELD NOT SWITCHING PROPERLY .....................14 P1594-CHARGING SYSTEM VOLTAGE TOO HIGH ...........................16 P1682-CHARGING SYSTEM VOLTAGE TOO LOW ............................18 COMMUNICATION P0600-PCM FAILURE SPI COMMUNICATIONS...............................21 P0601-PCM INTERNAL CONTROLLER FAILURE .............................21 i

P1685-WRONG OR INVALID KEY MSG RECEIVED FROM SKIM ................22 P1686-NO SKIM BUS MESSAGE RECEIVED ................................24 P1687-NO CLUSTER BUS MESSAGE ......................................26 P1696-PCM FAILURE EEPROM WRITE DENIED .............................28 P1697-PCM FAILURE SRI MILE NOT STORED...............................28 P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE ................30 DRIVEABILITY - GAS P0071 - AMBIENT TEMP SENSOR PERFORMANCE ..........................32 P0106-BAROMETRIC PRESSURE OUT OF RANGE ..........................34 P0107-MAP SENSOR VOLTAGE TOO LOW .................................37 P0108-MAP SENSOR VOLTAGE TOO HIGH .................................40 P0117-ECT SENSOR VOLTAGE TOO LOW ..................................43 P0118-ECT SENSOR VOLTAGE TOO HIGH .................................45 P0121-TPS VOLTAGE DOES NOT AGREE WITH MAP ........................48 P0122-THROTTLE POSITION SENSOR VOLTAGE LOW .......................53 P0123-THROTTLE POSITION SENSOR VOLTAGE HIGH ......................57 P0125-CLOSED LOOP TEMP NOT REACHED ...............................60 P0131-1/1 O2 SENSOR SHORTED TO GROUND .............................62 P0137-1/2 O2 SENSOR SHORTED TO GROUND .............................62 P0132-1/1 O2 SENSOR SHORTED TO VOLTAGE ............................65 P0138-1/2 O2 SENSOR SHORTED TO VOLTAGE ............................65 P0133-1/1 O2 SENSOR SLOW RESPONSE .................................68 P0139-1/2 O2 SENSOR SLOW RESPONSE .................................68 P0134-1/1 O2 SENSOR STAYS AT CENTER .................................71 P0140-1/2 O2 SENSOR STAYS AT CENTER .................................71 P0135-1/1 O2 SENSOR HEATER FAILURE ..................................74 P0141-1/2 O2 SENSOR HEATER FAILURE ..................................76 P0171-1/1 FUEL SYSTEM LEAN ...........................................78 P0172-1/1 FUEL SYSTEM RICH ...........................................83 P0201-INJECTOR #1 CONTROL CIRCUIT ...................................88 P0202-INJECTOR #2 CONTROL CIRCUIT ...................................88 P0203-INJECTOR #3 CONTROL CIRCUIT ...................................88 P0204-INJECTOR #4 CONTROL CIRCUIT ...................................88 P0300-MULTIPLE CYLINDER MIS-FIRE .....................................91 P0301-CYLINDER #1 MISFIRE ............................................91 P0302-CYLINDER #2 MISFIRE ............................................91 P0303-CYLINDER #3 MISFIRE ............................................91 P0304-CYLINDER #4 MISFIRE ............................................91 P0320-NO CRANK REFERENCE SIGNAL AT PCM ............................96 P0340-NO CAM SIGNAL AT PCM .........................................101 P0351-IGNITION COIL #1 PRIMARY CIRCUIT ..............................106 P0352-IGNITION COIL #2 PRIMARY CIRCUIT ..............................106 P0420-1/1 CATALYTIC CONVERTER EFFICIENCY...........................109 P0441-EVAP PURGE FLOW MONITOR ....................................111 P0442-EVAP LEAK MONITOR MEDIUM (.040) LEAK DETECTED ...............114 P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED .....................114 P0456 - EVAP LEAK MONITOR SMALL LEAK DETECTED ....................114 P0443-EVAP PURGE SOLENOID CIRCUIT .................................117 P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES........................120 P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW.......................123 P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH ......................123 P0500-NO VEHICLE SPEED SIGNAL ......................................125 ii

P0500-NO VEHICLE SPEED SIGNAL ......................................128 P0508 - IAC MOTOR SENSE CIRCUIT LOW ................................131 P0509 - IAC MOTOR SENSE CIRCUIT HIGH ...............................134 P0551-POWER STEERING SWITCH FAILURE ..............................136 P0700-EATX CONTROLLER DTC PRESENT................................138 P0703-BRAKE SWITCH SENSE CIRCUIT ..................................139 P0740-TORQ CONV CLU, NO RPM DROP AT LOCKUP ......................142 P0743-TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIRCUITS. . .145 P0833-CLUTCH RELEASED SWITCH CIRCUIT .............................148 P1192-INLET AIR TEMP SENSOR VOLTAGE LOW...........................151 P1193-INLET AIR TEMP SENSOR VOLTAGE HIGH ..........................153 P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR ................155 P1281-ENGINE IS COLD TOO LONG......................................157 P1282-FUEL PUMP RELAY CONTROL CIRCUIT.............................158 P1289-MANIFOLD TUNE VALVE CONTROL CIRCUIT ........................161 P1294-TARGET IDLE NOT REACHED .....................................164 P1297-NO CHANGE IN MAP FROM START TO RUN .........................166 P1299-VACUUM LEAK FOUND (IAC FULLY SEATED) ........................170 P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT.......................172 P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM .........................175 P1390-TIMING BELT SKIPPED 1 TOOTH OR MORE .........................178 P1391-INTERMITTENT LOSS OF CMP OR CKP.............................179 P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT .........................183 P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND ......................185 P1490-LOW SPEED FAN CONTROL RELAY CIRCUIT ........................188 P1494-LEAK DETECT PUMP SW OR MECHANICAL FAULT ...................191 P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT .......................193 P1496-5 VOLT SUPPLY, OUTPUTTOO LOW ...............................195 P1602-PCM NOT PROGRAMMED ........................................198 P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (3SP AUTO TRANS) ........199 P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (4SP AUTO TRANS) ........201 *CHECKING ECT SENSOR ..............................................203 *CHECKING FUEL DELIVERY ............................................204 *CHECKING IAT SENSOR ...............................................207 *CHECKING MAP SENSOR ..............................................208 *CHECKING PCM POWER AND GROUND CIRCUITS ........................209 *CHECKING RADIATOR FAN RELAY OUTPUT ..............................210 *CHECKING THE A/C RELAY OUTPUT ....................................212 *CHECKING THE EVAP SYSTEM .........................................214 *CHECKING TP SENSOR ...............................................216 HEATING & A/C P0645-A/C CLUTCH RELAY CKT .........................................217 SPEED CONTROL P1595-SPEED CONTROL SOLENOID CIRCUITS ............................220 P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT ...................220 P1597-SPEED CONTROL SWITCH ALWAYS LOW ...........................225 STARTING *ENGINE CRANKS DOES NOT START ....................................227 *NO CRANK CONDITION................................................232 iii

*NO RESPONSE FROM PCM WITH A NO START CONDITION ................235 *START AND STALL CONDITION .........................................236 VEHICLE THEFT/SECURITY ANTENNA FAILURE ....................................................240 COP FAILURE .........................................................240 EEPROM FAILURE .....................................................240 INTERNAL FAULT ......................................................240 RAM FAILURE.........................................................240 SERIAL LINK INTERNAL FAULT ..........................................240 STACK OVERFLOW FAILURE............................................240 PCM STATUS FAILURE .................................................242 SERIAL LINK EXTERNAL FAULT .........................................242 ROLLING CODE FAILURE ...............................................244 VIN MISMATCH ........................................................244 TRANSPONDER COMMUNICATION FAILURE ..............................246 TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE .............246 TRANSPONDER ID MISMATCH ..........................................246 TRANSPONDER RESPONSE MISMATCH ..................................246 VERIFICATION TESTS VERIFICATION TESTS ..................................................249 8.0 COMPONENT LOCATIONS ..............................................255 8.1 CONTROL MODULES AND PDC.....................................255 8.2 CONTROLS AND SOLENOIDS ......................................255 8.3 DATA LINK CONNECTOR ..........................................256 8.4 SENSORS .......................................................257 8.5 FUEL SYSTEM ...................................................258 8.6 SWITCHES ......................................................259 8.7 SPECIFICATIONS .................................................260 9.0 CONNECTOR PINOUTS ................................................261 A/C COMPRESSOR CLUTCH - BLACK 2 WAY ..............................261 BRAKE LAMP SWITCH - 6 WAY ..........................................261 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY .......261 CAMSHAFT POSITION SENSOR - BLACK 3 WAY ...........................261 CLOCKSPRING - GREEN 7 WAY .........................................262 CLUTCH INTERLOCK/UPSTOP SWITCH (MTX) - BLACK 3 WAY ...............262 CRANKSHAFT POSITION SENSOR - BLACK 3 WAY .........................262 DATALINK CONNECTOR - BLACK 16 WAY ................................262 ENGINE COOLANT TEMPERATURE SENSOR (2.0L) - BLACK 2 WAY ..........263 ENGINE OIL PRESSURE SWITCH - GREEN 2 WAY .........................263 EVAP PURGE SOLENOID (SOLENOID SIDE) ...............................263 FUEL INJECTOR NO. 1 - BLACK 2 WAY ...................................263 FUEL INJECTOR NO. 2 - BLACK 2 WAY ...................................264 FUEL INJECTOR NO. 3 - BLACK 2 WAY ...................................264 FUEL INJECTOR NO. 4 - BLACK 2 WAY ...................................264 FUELPUMP MODULE - LT. GRAY 4 WAY ..................................264 GENERATOR - BLACK 2 WAY ...........................................264 IDLE AIR CONTROL MOTOR (2.0L) - BLACK 2 WAY .........................265 IGNITION COIL - BLACK 3 WAY ..........................................265 iv

IGNITION SWITCH - BLACK 10 WAY ......................................265 GENERATOR (GENERATOR SIDE) .......................................265 INLET AIR TEMPERATURE SENSOR - BLACK 2 WAY........................266 INPUT SPEED SENSOR (EATX) - GRAY 2 WAY .............................266 INSTRUMENT CLUSTER - BLACK 26 WAY .................................267 FUSES (LHD) .........................................................269 CIRCUIT BREAKERS (LHD) .............................................269 FUSES (RHD) .........................................................271 CIRCUIT BREAKERS (RHD) .............................................271 KNOCK SENSOR (2.0L) - BLACK 2 WAY...................................272 LEAK DETECTION PUMP (EXCEPT BUILT-UP-EXPORT) - BLACK 4 WAY .......272 MANIFOLD ABSOLUTE PRESSURE SENSOR - 3 WAY .......................272 MANIFOLD TUNING VALVE SOLENOID (RT) - BLACK 2 WAY .................272 OUTPUT SPEED SENSOR (EATX) - GRAY 2 WAY ...........................272 OXYGEN SENSOR 1/1 UPSTREAM - BLACK 4 WAY .........................273 OXYGEN SENSOR 1/2 DOWNSTREAM - BLACK 4 WAY .....................273 PARK/NEUTRALPOSITION SWITCH (ATX) - BLACK 3 WAY...................273 FUSES (PDC) .........................................................275 A/C COMPRESSOR CLUTCH RELAY......................................275 AUTOMATIC SHUT DOWN RELAY ........................................275 ENGINE STARTER MOTOR RELAY .......................................275 FUEL PUMP RELAY ....................................................276 MANIFOLD TUNING VALVE RELAY (RT PACKAGE) ..........................276 RADIATOR FAN RELAY .................................................276 POWER STEERING PRESSURE SWITCH - GRAY 2 WAY ....................277 POWERTRAIN CONTROL MODULE C1 (2.0L) - BLACK 40 WAY ...............277 POWERTRAIN CONTROL MODULE C2 (2.0L) - BLACK 40 WAY ...............278 RADIATOR FAN MOTOR - BLACK 2 WAY ..................................279 SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY ......................279 THROTTLE POSITION SENSOR - BLACK 3 WAY ...........................279 TORQUE CONVERTER CLUTCH SOLENOID (ATX) - BLACK 3 WAY............279 TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY ...............280 TRANSMISSION RANGE SENSOR (EATX) - DARK GRAY 10 WAY .............281 VEHICLE SPEED SENSOR - BLACK 3 WAY ................................281 10.0 SCHEMATIC DIAGRAMS................................................283 10.1 2000 PL 2.0L Engine ...............................................283 v

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Euro Stage III OBD MONITOR INFORMATION Comprehensive Major Monitors 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 Two Trip Faults - Turns On The MIL and Sets DTC After The MIL and Sets DTC After The MIL and Sets DTC After One Failure Two Consecutive Failures 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 Efficiency Except EWMA To Extinguish The MIL Outputs Checked For - up to 6 tests per trip Functionality and a one trip fault EGR System Misfire Monitor Evaporative Emission Monitors For Engine Misfire System at: (Purge and Leak) 1000 RPM Counter Non-LDP (Type B) or **200 RPM Counter LDP (Type A) Requires 3 Consecutive Requires 3 Consecutive Requires 3 Consecutive to Extinguish the MIL* to Extinguish the MIL* To Extinguish the MIL *40 Warm Up Cycles are required to erase **Type A misfire is a two DTC’s the MIL has been extinguished. trip failure. The MIL will illuminate and blink at the first failure. 3

2005 Dodge Neon Service & Repair Manual

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