Short & Sweet Version:
2000 Grand Caravan (3.3L) cranks but doesn’t run. If I bypass the automatic shut-down relay it’ll run for about 3 seconds, but starts surging and conks out. Both the cam & crank position sensors test okay. What other sensor(s) might be telling the PCM (PowertrainControlModule) that it shouldn’t let the engine run (not energizing the automatic shutdown relay)?
The rest of story (with extra clues):
After several problem-free years, the engine mysteriously died a few times while driving, but started back up immediately, and then twice it took several tries to start from cold. The last day, I drove it for 2 very short errands without incident, and then it refused to start, permanently.
Usually, when I find fried wires I can trace them and figure out the cause; not so with this trickster. Two of the three leads to the camshaft position sensor had gotten hot enough to make the insulation shrivel up leaving about 3" of each lead completely bare. The odd thing is, the lead that supplied the power in the circuit is the one that didn’t get fried. Well, I replaced that sensor with a known good one but the engine still just cranked without firing.
Traced the cause to the automatic shutdown relay; it wasn’t sending juice to the ignition system and the fuel injectors. But the relay tested out perfectly.
For some reason, the PCM is not sending a signal to the automatic shutdown relay authorizing it to shoot some juice on over there.
So I hot-wired 12V directly to the ignition coil pack and fuel injectors…and got spark and fuel. This arrangement gets the engine to run nicely for about 3 secs before it starts surging, and then within about another 3 secs it dies.
I’m guessing that the root of this problem is probably another sensor that’s telling the PCM that something is whacko enough that the PCM should not authorize the auto-shutdown relay to let the engine run.
Both the cam & crank position sensors check out okay. Whatever sensor is the cause had a few intermittent episodes over several weeks. The wires to the cam pos’n sensor were fried, but may not have been involved with the underlying problem.
By the way, the 3 wires on the cam pos’n sensor are:
Org 8v supply from PCM
Blk/LtBlu Sensor ground back to PCM
Tan/Yel Sensor signal back to PCM {5.0volts and 0.5volts, alternately}
And, somehow, enough power passed thru the last two wires to cause their insulation to shrivel up leaving nearly 3 inches of the wires bare!
Who has an idea of what could be going on?