Chrysler PT Cruiser. Manual - part 370

TEST

ACTION

APPLICABILITY

t, actuate the ASD Fuel System test and observe the fuel pressure

gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.

All

Below Specification

Go To

Within Specification

Go To

Above Specification

Replace the fuel filter/fuel pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

Caution: Stop All Actuations.

Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16 fuel line adapter tool #6539 between the disconnected fuel line
and the fuel pump module.
Attach a fuel pressure test gauge to the

9T9 fitting on tool #6539.

Turn the ignition on.
With the DRBIII

t, actuate the ASD Fuel System test and observe the fuel pressure

gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Is the fuel pressure within specification now?

All

Yes

→ Repair/replace fuel supply line as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

→ Go To 5

Caution: Stop All Actuations.

All

Yes

→ Replace the Fuel Pump Inlet Strainer.

Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

→ Replace the Fuel Pump Module.

Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

570

STARTING

*START AND STALL CONDITION 2.0L/2.4L —

Continued

TEST

ACTION

APPLICABILITY

Turn the ignition on.
With the DRBIII

t, read TPS VOLTS.

While monitoring the DRBIII

t, slowly open and close the Throttle.

Is the voltage change smooth?

All

Yes

→ Go To 7

→ Replace the Throttle Position Sensor.

Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

Turn the ignition on.
With the DRBIII

t, read Throttle Position voltage. Throttle must be against stop.

Is the voltage 0.92 or less with the Throttle closed?

All

Yes

→ Go To 8

→ Check for a binding throttle condition. If OK, replace the Throttle

Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soaked).
NOTE: If the vehicle was allow to sit over night with no engine start, coolant
temperature should be near ambient temperatures.
Turn the ignition on.
With the DRBIII

t, read the Engine Coolant Temperature value.

Note: If engine coolant temperature is above 82° C (180° F), allow the engine
to cool until 65° C (150° F) is reached.
Start the engine.
During engine warm-up, monitor the Engine Coolant Temperature value. The
temperature value change should be a smooth transition from start up to normal
operating temp 82° C (180° F). The value should reach at least 82° C (180° F).
Did the Engine Temperature value increase smoothly and did it reach at least 82° C
(180° F)?

All

Yes

→ Go To 9

→ Replace the Engine Coolant Temperature Sensor.

Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

The following additional items should be checked as a possible cause for a start and
stall condition.
Refer to any Technical Service Bulletins (TSB’s) that may apply to the symptom.
Fuel must be free of contamination.
The exhaust system must be free of any restrictions.
The engine compression must be within specifications.
The engine valve timing must be within specifications.
The engine must be free from vacuum leaks.
The throttle body must be free of carbon buildup and dirt.
Do any of the above conditions exist?

All

Yes

→ Repair as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.

→ Test Complete.

571

STARTING

*START AND STALL CONDITION 2.0L/2.4L —

Continued

Verification Tests

40/41TE (NGC) TRANSMISSION VERIFICATION TEST - VER 1

APPLICABILITY

1. NOTE: After completion of the Transmission Verification Test, the Powertrain
Verification Test must be performed. Refer to the Powertrain Category.
2. Connect the DRBIII

t to the Data Link Connector (DLC).

3. Reconnect any disconnected components.
4. With the DRBIII

t, erase all Transmission DTC’s, also erase the PCM DTC’s.

5. Perform *PRNDL FAULT CLEARING PROCEDURE after completion of repairs for P0706
CHECK SHIFTER SIGNAL.
6. With the DRBIII

t, display Transmission Temperature. Start and run the engine until the

Transmission Temperature is HOT, above 43° C or 110° F.
7. Check the transmission fluid and adjust if necessary. Refer to the Service Information for the
Fluid Fill procedure.
8. NOTE: If the Transmission Control Module or Torque Converter has been replaced,
or if the Transmission has been repaired or replaced, it is necessary to perform the
DRBIII

t Quick Learn Procedure and reset the (Pinion Factor(.

9. Road test the vehicle. With the DRBIII

t, monitor the engine RPM. Make 15 to 20 1-2, 2-3,

3-4 upshifts. Perform these shifts from a standing start to 45 MPH with a constant throttle
opening of 20 to 25 degrees.
10. Below 25 MPH, make 5 to 8 wide open throttle kickdowns to 1st gear. Allow at least 5
seconds each in 2nd and 3rd gear between each kickdown.
11. For a specific DTC, drive the vehicle to the Symptom’s When Monitored and Set Conditions
to verify the DTC is repaired.
12. If equipped with AutoStick

t, upshift and downshift several times using the AutoStickt

feature during the road test.
13. NOTE: Use the EATX OBDII task manager to run Good Trip time in each gear, this
will confirm the repair and to ensure that the DTC has not re-matured.
14. Check for Diagnostic Trouble Codes (DTC’s) during the road test. If a DTC sets during the
road test , return to the Symptom list and perform the appropriate symptom.
15. NOTE: Erase P0700 DTC in the PCM to turn the MIL light off after making
transmission repairs.
Were there any Diagnostic Trouble Codes set during the road test?

All

Yes

→ Repair is not complete, refer to the appropriate symptom.

→ Repair is complete.

BODY VERIFICATION TEST - VER 1

APPLICABILITY

1. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
2. NOTE: If the SKIM or PCM/ECM was replaced, refer to the service information for
proper programming procedures.
3. NOTE: PT27 ONLY: If a Window Regulator Module was replaced, close both doors,
raise both door windows fully up and hold the switch in the up position for 2
additional seconds then use the DRBIII to

(Initialize Module(.

4. Program all RKE transmitters and other options as necessary.
5. Ensure that all accessories are turned off and the battery is fully charged.
6. With the DRBIII

t, record and erase all DTC’s from ALL modules. Start and run the engine

for 2 minutes. Operate all functions of the system that caused the original concern.
7. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII

t, read

DTC’s from ALL modules.
Are any DTC’s present or is the original condition still present?

All

Yes

→ Repair is not complete, refer to the appropriate symptom.

→ Repair is complete.

572

VERIFICATION TESTS

CHARGING VERIFICATION - VER-3

APPLICABILITY

1. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
2. With the DRB, erase all diagnostic trouble codes (DTCs).
3. Start the engine.
4. Raise the engine speed to 2000 RPM for at least 30 seconds.
5. Allow the engine to idle.
6. Turn the ignition off for 20 seconds.
7. Turn the ignition on.
8. With the DRB, read ECM DTCs.
9. If this DTC has set again, or another DTC has set, look for any Technical Service Bulletins
(TSBs) that may relate to this condition. Return to the Symptom List if necessary.
10. If the charging system is functioning correctly and there are no DTCs, the repair is now
complete.
Are any DTCs or symptoms remaining?

All

Yes

→ Repair is not complete, refer to appropriate symptom.

→ Repair is complete.

NO START VERIFICATION - VER-1

APPLICABILITY

1. NOTE: IMPORTANT! If the Engine Control Module or Sentry Key Immobilizer
Module has been replaced, ensure the programming procedure for the module has
been performed in accordance with the Service Information.
2. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Turn the ignition off for at least 10 seconds.
6. Attempt to start the engine.
7. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may
relate to this condition. Return to the Symptom List if necessary.
8. If the engine starts and continues to run, the repair is now complete.
Are any DTCs or symptoms remaining?

All

Yes

→ Repair is not complete, refer to appropriate symptom.

→ Repair is complete.

573

VERIFICATION TESTS

Verification Tests —

Continued

Content .. 368 369 370 371 ..