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Dodge Repair/1996 Dodge Grand Caravan Will Not Start (Continued)


Hi Roland,

    Thanks again for all the help and the continuation of your assistance in this matter.

    I rechecked the code three more times and still get the 1-2-2-4-5-5 reading.

    I checked the voltage with the gas pedal being pressed.  It registered from 1v to 3.93v, with a slight various in the higher reading each time the pedal was pressed.

Thanks again!

That sounds alright on the voltage. And is it the case that you verified the same voltage range to be seen at the wires for the signal and the ground at the PCM plug? You can insert a fine pin through the insulation of each wire and take your reading off those pins. The orange/dark blue is on pin 35 while the black/light blue is on pin 43.
If that voltage check of the tps is OK them the next step would be to look at the egr valve.
My suspicion would be that your egr valve is sticking slightly ajar which will cause the engine to falter at idle speed or be hard to start. The valve is located near the throttle body air intake at the end of the engine, mounted in a small diameter pipe that recirculates exhaust gas from the rear cylider bank exhaust manifold back around to just below the intake manifold where the air from the filter enters the throttle body. The exhaust gases have some fumes that can plate out a crud on the valve stem and thus keep it from closing tight when you are start or at idle. That makes for a too lean mixture so the engine stalls. The valve proper is mounted horizontally with the stem visible in a space between the body of the valve mounted on the pipe and the round top of the valve which is flanged and so if you look carefully you will see a metal rod (stem of the valve) with a slot around its circumference. You can take the tip of flat blade screwdriver and insert it in the slot and then lever the valve back and forth to check if it is moving freely (against spring action in one direction) or not. If it doesn't seem to close easily with the help of the built-in spring, then I would spray the base of the stem with solvent from a pressure can (such as WD-40 or carb cleaner) while moving the stem back and forth. See if that makes it run better upon starting.

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Roland Finston


Free fast answer to your repair question about a Chrysler/Dodge/Plymouth car, minivan, SUV, or truck. Problems with electronically controlled engines and transmissions as well as body wiring problems are my specialty. This free troubleshoot advice forum helps you diagnose faults, minimize repair costs or do-it-yourself.

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