Diagnostic Test

READ AND RECORD DTCS AND ENVIRONMENTAL DATA - ERASE DTCS AND CHECK FOR DTC TO RETURN
1. With the scan tool, read DTCs in all Electronic Control Units (ECUs) and record on the repair order.
2. For future reference, with the scan tool, run and save a vehicle Scan Report and all related recorded data.
3. With the scan tool, erase all DTCs.
4. Turn the ignition off for a minimum of 10.0 seconds.
5. Turn the ignition on.
6. Using the When Monitored and Set Conditions above and recorded data, operate the vehicle in the conditions that set the DTC.
7. With the scan tool, read DTCs.
  Did the DTC return?
  
  Yes
  - Go To 2
  No
  - Perform the INTERMITTENT CONDITION diagnostic procedure. Refer to INTERMITTENT CONDITION .
CHECK THE STARTER RELAY AND PDC FOR PROPER OPERATION
NOTE:
This step is intended to energize the relay coil.
1. Using a 12-volt test light connected to Fused B+, back probe the Starter Relay Control circuit at the PDC connector.
  NOTE:
  The relay should make an audible click when closing.
  
  Does the Starter Relay click when the control circuit is connected to Fused B+?
  
  Yes
  - Go To 3
  No
  - Go To 5

ISOLATE AND LOAD TEST THE STARTER RELAY CONTROL CIRCUIT

NOTE:

Note: Why load test a circuit? A load test is used to determine if a circuit is capable of carrying the amperage needed to perform properly. The 3156 bulb in the load tool illustrated, is a simple but effective method of testing circuit functionality. A 3156 Bulb has approximately 6.0 Ohms of resistance when the bulb is powered and draws approximately 2.0 amps. Read the CIRCUIT LOAD TESTING PROCEDURE for information on building a simple load test tool and for additional load testing information and alternative methods of load testing or voltage drop testing a circuit. Refer to CIRCUIT LOAD TESTING PROCEDURES .

NOTE:

Note: A 12-volt test light can be substituted for the load test tool, but only if the test light draws enough current to effectively load test the circuit. Many high impedance test lights draw very little amperage (less than 0.1 amps) and are not reliable to load test a circuit.

NOTE:

Note: Perform a Voltage Drop Test across the 3156 bulb of the load test tool to verify with certainty there is no resistance in the circuit being tested. To do so perform the following:

Connect the leads of a DVOM to the alligator clips on the load test tool while the load test tool is connected in series with the circuit.
Compare the voltage drop across the bulb to the voltage reading across the Battery terminals.
The voltage dropped across the bulb should be equal to the voltage reading across the Battery terminals if there is no resistance in the circuit being tested.

Example: 2.0 Ohms of resistance in the circuit will cause the voltage measurement across the bulb to be 25% less than when compared to Battery voltage. The reason for this is that the 2.0 Ohms in the circuit makes up 25% of the total circuit resistance of 8.0 Ohms.

NOTE:

Read the CIRCUIT LOAD TESTING PROCEDURE for information on building a simple load test tool and for additional load testing information and alternative methods of load testing or voltage drop testing a circuit. Refer to CIRCUIT LOAD TESTING PROCEDURES .

CAUTION:

Do not load test any circuits with components still connected to the circuit.

Turn the ignition off when performing the load test on the circuit.
Remove the 12-volt test light.
Remove the Starter Relay from the PDC.
Disconnect the appropriate PCM harness connector. Do not disconnect any in-line harness connectors at this time.
Connect the electrical test lead kit to the appropriate terminal in the PCM harness connector.
(special tool #2064100080, Kit, Electrical Test Lead)
Connect the positive lead of the load test tool to the positive side of the Battery (A). Note: . Refer to the example illustration below as an example of how to connect the load test tool.
Connect the negative lead of the load test tool to the electrical test lead tool connected to the relay socket (B).
Connect a jumper between the negative side of the Battery or a known good ground and the Starter Relay Control circuit at the PCM harness connector (C and D).

The bulb on the load test tool should be illuminated and bright if there is no resistance in the circuit.

Courtesy of CHRYSLER GROUP, LLC

NOTE:

Compare the brightness of the bulb in the load test tool to that of a direct connection to Battery.

Is the load test bulb illuminated and bright?

Yes

Go To 4

Repair the Starter Relay Control circuit for an open or short to ground.
Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

CHECK RELATED PCM AND COMPONENT CONNECTIONS
1. Perform any Service Bulletins that apply.
2. Disconnect all PCM harness connectors.
3. Disconnect all related in-line harness connections (if equipped).
4. Disconnect the related component harness connectors.
5. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
  - Proper connector installation.
  - Damaged connector locks.
  - Corrosion.
  - Other signs of water intrusion.
  - Weather seal damage (if equipped).
  - Bent terminals.
  - Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
  - Terminals that have been pushed back into the connector cavity.
  - Check for spread terminals and verify proper terminal tension.
  Repair any conditions that are found.
6. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
9. With the scan tool, erase DTCs.
10. Test drive or operate the vehicle in accordance with the when monitored and set conditions.
11. With the scan tool, read DTCs.
  Did the DTC return?
  
  Yes
  - Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - The wiring or poor connection problem has been repaired.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

CHECK THE GROUND CIRCUIT FOR HIGH RESISTANCE BY LOAD TESTING THE CIRCUIT AT THE RELAY SOCKET

NOTE:

Note: Perform a Voltage Drop Test across the 3156 bulb of the load test tool to verify with certainty there is no resistance in the circuit being tested. To do so perform the following:

Connect the leads of a DVOM to the alligator clips on the load test tool while the load test tool is connected in series with the circuit.
Compare the voltage drop across the bulb to the voltage reading across the Battery terminals.
The voltage dropped across the bulb should be equal to the voltage reading across the Battery terminals if there is no resistance in the circuit being tested.

NOTE:

Turn the ignition off.
CAUTION:
Do not load test any circuits with components still connected to the circuit.
Remove Starter Relay from the PDC.

Load test the Ground circuit at the relay socket (85 or 86) in the PDC (A). Note: refer to the example illustration below as an example of how to connect the load test tool.

Courtesy of CHRYSLER GROUP, LLC

NOTE:

The bulb on the load test tool should be illuminated and bright if there is no resistance in the circuitry. Compare the brightness of the bulb in the load test tool to that of a direct connection to Battery.

Is the load test bulb illuminated and bright?

Yes

Replace the Starter Relay in accordance with the Service Information.
Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

Go To 6

ISOLATE AND CHECK THE STARTER RELAY CONTROL CIRCUIT FOR A SHORT TO GROUND
1. The ignition must be off when checking a circuit for continuity to ground.
2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and every component harness connector containing the circuit being tested. Note: Use the wiring diagram as a guide to follow the path of the circuit.
3. Connect the negative lead of the DVOM to a known good ground.
4. With the positive lead of the DVOM, probe the circuit being tested at the component harness connector and check for continuity between the circuit and ground.
NOTE:
There should be no continuity between ground and the circuit being tested.

Is there continuity between ground and the circuit being tested?

Yes
- Repair the circuit for a short to ground. Use the wiring diagram as a guide to trace the circuit and look for any in-line connectors to help isolate the location of the short.
- Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
No
- Go To 7
ISOLATE AND CHECK THE STARTER RELAY CONTROL CIRCUIT FOR A SHORT TO ANOTHER VOLTAGE SUPPLY CIRCUIT AT THE PCM HARNESS CONNECTOR
1. The ignition must be off when performing a resistance check to find a short between circuits.
2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and every component harness connector containing the circuit being tested. At this time leave all in-line connectors connected. Note: Use the wiring diagram as a guide to follow the path of the circuit.
3. Connect one lead of the DVOM to the circuit being tested at the ECU harness connector.
4. With the other lead of the DVOM probe all other circuits at the ECU harness connector.
CAUTION:
Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.
1. If it is necessary to probe a terminal at a PCM harness connector, connect the adapter to the appropriate PCM harness connector.
  (special tool #10436, Adapter, GPEC Diagnostic)
  
  NOTE:
  With the circuit isolated there should be no continuity between the circuit being tested and any other circuit.
  
  Is there continuity between the circuit being tested and any other circuit?
  
  Yes
  - Repair the short between the circuits that have continuity. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors to help isolate the location of the short.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Replace the Starter Relay in accordance with the Service Information.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .