Mechanics

TURN THE KEY TO START AND NOTHING HAPPEN

2002 Dodge Caravan

Electrical problem
2002 Dodge Caravan 6 cyl Two Wheel Drive Automatic 147000 miles

The problem is simple. Turn the key to �start� and nothing happens but the starter relay comes on.

The van has been driving normal for 3 months now. I had a new PCM and Map sensor installed three months ago. No signs of problems at all. The wife drove it home, parked it for 3 or 4 days and this happened.

One problem exists with the key off.
1. The steering wheel does not lock in the park position. I don�t know how long this has been the case.

This is what I have with the key in the on position.
1. All dash lights are on as normal.
2. I can hear the fuel pump coming on and hum.
3. I can hear the injectors (or something in the immediate area) click and hum.
4. All other controls work. Ex. Heater, radio, lights, and even the back up lights in reverse.
5. The gearshift shows it in park and it switches through the gears correctly. (Yes, I have tried starting in neutral. Lol)

Here are the parts that I have checked and tested to be good.
1. Starter (new and tested)
2. Battery (new and trickle charged 12.65 volts)
3. All relays and all fuses in the relay box (metered with power and off)
4. Voltages are present at the starter and ground is good on the battery.
5. The control wire from the starter to the relay ohms out good.
6. All connections have been cleaned and tests good.
7. The PCM has worked fine for three months. It�s from AutoZone and had been flashed and coded with my VIN. (Don�t know if it is bad or good now.)

The neutral positioning switch is incased in the tranny (non-removable) and is a 6 (I think) pole plug. Hanes book doesn�t even cover this type of switch. All others are removable 3 pole switches.

I have no engine codes when I try the key method. (On, off, on, off, on)

I tried a completely separate circuit/switch for the starter. With the key both in the on position and start position, in neutral and park. It cranked the engine but no spark was present to the plugs.

One thing to note, when I try to start with the key as normal, the radio shuts off when the key is in the start position.

I have almost totally given up. What next.

Thanks
Avatar
Choochstr
August 20, 2010.



No start testing as follows, I will email the C! & C2 connector info so you can read and print.
NO CRANK CONDITION 1. Disconnect negative battery cable and wait 2 minutes. Turn engine over by hand to ensure engine is not seized. If engine is not seized, go to next step. If engine is seized, repair mechanical condition preventing engine from cranking. 2. Ensure ignition is off. Reconnect negative battery cable. Disconnect PCM harness connectors. PCM is located on left side of engine compartment, near front of battery. See Fig. 2 . Measure resistance between ground and Yellow/Dark Blue wire at terminal No. 76 at PCM C2 harness connector. See Fig. 6 . Shift transmission through all gears, from Park to 1st and back. Resistance should be less than 10 ohms when transmission is in Park or Neutral, then switch to more than 10 ohms when transmission is not in Park or Neutral. If resistance is as specified, go to next step. If resistance is not as specified, replace transmission range sensor. 3. Connect voltmeter negative lead to negative battery terminal. Connect voltmeter positive lead to engine block, near negative battery cable grounding point. Crank engine and observe voltmeter. If voltmeter indicates .2 volt or less, go to next step. If voltmeter indicates more than .2 volt, repair poor ground connection or replace ground cable. 4. Remove starter heat shield (if equipped) to gain access to starter solenoid connections. Connect voltmeter negative lead to starter solenoid battery terminal and voltmeter positive lead to positive battery terminal. Crank engine and observe voltmeter. If voltmeter indicates .2 volt or less, go to next step. If voltmeter indicates more than .2 volt, repair poor connection between battery cable and starter solenoid or replace positive battery cable. 5. Ensure ignition is off. Remove starter relay from Intelligent Power Module (IPM) on left side of engine compartment, next to battery. See Fig. 2 . Briefly connect a jumper wire between terminals No. 30 and 87 at starter relay socket in IPM. See Fig. 3 . If engine cranks, go to next step. If engine does not crank, go to step 9 . 6. Connect a test light between ground and terminal No. 86 at starter relay socket in IPM. While NOTE: For circuit identification and wiring diagram, see WIRING DIAGRAMS article. If Powertrain Control Module (PCM) is replaced, PCM must be reprogrammed. See PROGRAMMING . After each repair procedure has been completed, reconnect all components. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS to ensure system is functioning properly. NOTE: Ensure that Sentry Key Immobilizer System (SKIS) is operating properly. Check the Sentry Key Immobilizer Module (SKIM) for DTCs. If a SKIM DTC (P-code) is present, diagnose SKIM DTC(s) before continuing with this test. See SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER article. If any SKIM DTC (fault) messages are present, a fault exists in anti-theft system. Perform appropriate test. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. WARNING: Engine may crank during the following step. Ensure transmission is in Park and parking brake is applied. Keep away from moving engine parts. observing test light, turn ignition switch to START position. If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or high resistance in ignition switch output circuit (Yellow wire). See WIRING DIAGRAMS in appropriate STARTERS article in STARTING & CHARGING SYSTEMS. 7. Turn ignition off. Disconnect PCM harness connectors. Measure resistance of Dark Green/Orange wire between terminal No. 85 at starter relay socket in IPM and terminal No. 31 at PCM C1 harness connector. See Fig. 3 and Fig. 7 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Green/Orange wire. 8. Reconnect PCM harness connectors. Install a substitute relay in place of starter relay. Attempt to start engine. If engine cranks, replace starter relay. If engine does not crank, replace PCM. 9. Disconnect starter solenoid harness connector. Measure resistance of Yellow/Gray wire between terminal No. 87 at starter relay socket in IPM and terminal No. 1 at starter solenoid harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow/Gray wire. 10. Connect a test light between ground and terminal No. 30 at starter relay socket in IPM. See Fig. 3 . If test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair open or high resistance in Red wire between battery and starter relay. Also check fuse No. 9 (40-amp) in IPM. 11. If no other possible causes are remaining, replace starter.


http://www.2carpros.com/forum/automotive_pictures/62217_IPM_2.jpg



http://www.2carpros.com/forum/automotive_pictures/62217_PCM_12.jpg


Merlin2021
Aug 20, 2010.
Ok. This is a 2002 grand caravan. The park/neutral saftey switch is in cased in the side of the tranny. And is rectangle approx. 1" x2". Hanes book only talks about a screw out type with 3 poles(conections). This one has 6.

What am I looking at now. Is there a way to pull the plug? I know autozone doesn't even offer the part.

Am I gonna have to pull the tranny?

Tiny
Choochstr
Aug 21, 2010.
Grand caravan has a few models, ES, EX, EL, SE, and sport, which do you have?
DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case ( Fig. 397 ). Fig. 397: Locating Transmission Range Sensor (TRS) Courtesy of DAIMLERCHRYSLER CORP. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM ( Fig. 398 ). Fig. 398: Locating Transmission Temperature Sensor Courtesy of DAIMLERCHRYSLER CORP. OPERATION The Transmission Range Sensor (TRS) ( Fig. 397 ) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure.


http://www.2carpros.com/forum/automotive_pictures/62217_TR_1.jpg



http://www.2carpros.com/forum/automotive_pictures/62217_TR_Specs_1.jpg


Merlin2021
Aug 22, 2010.
After checking again and understanding a little more, I don't think it is the neutral safety switch. I really appreciate your help. I will do more troubleshooting this week and see if I can narrow it down some more.

Tiny
Choochstr
Aug 23, 2010.
BTW your codes reading may be flawed, turn key on, off, on, off, on, off, and then leave it on.

Merlin2021
Aug 23, 2010.