Chrysler Repair: 99 Chrysler 3.8L: no start problem solved/pcm harness wires melted together, diagnostic scanner, fuse panel


Question
QUESTION: I have a 1999 Chrysler T&C limited van.  Another tech at this site gave some things to test via both fuse panel under dash and PDC under hood.

All fuses and connections have tested hot and working properly.  A diagnostic scanner was hooked up and shows no codes.  (It is a 16 pin with its own battery source)  The mechanic jiggled the key and instrument panel light went on and off - he turned the key with scanner hooked in and it started right up.  As soon as he unplugged scanner from vehicle - it went dead.  It will not start up without that scanner being plugged into the vehicle.

We replaced the ignition switch and found a yellow wire that goes to solenoid was connected improperly/cut from a previous install of an ignition switch 6 yrs ago.  That has been resolved, a new ignition switch installed and van re-booted.. but STILL the car will turn over, BUT won't start up unless the diagnostic scanner is plugged into the vehicle....Any ideas what to check next???

Many thanks for ANY input you might have - we are ALL scratchin our heads and sweating!!
Regards,
Morgan

ANSWER: Hi Morgan,
"Kevin" took a 'pass' on your problem. Did it get fixed yet?
Roland

---------- FOLLOW-UP ----------

QUESTION: Roland!

I sent this question out to cyberspace or rather the only other contact that Sunday while during our session last Sunday I got blocked by this website with a message "too many follow up questions" arrived and I could not reach you....BUT you since reached US with a TREMENDOUS help.  Your last email regarding checking the lines from the pcm and tmc and pointing to pins 10 & 50 were the clincher!!  Brian called this morning to BOTH our cheers!  He found a group of wires coming FROM the tcm that were literally melted together. Both grounds that from that group tied into the main ground.  He cut them apart and just to be sure, tested it by putting a clean ground from that area (?) hooked up the battery and it started right up!!  (I am not explaining this very well, but there ya go) Thanks to you pin pointing where to start - he found the area.  We are both amazed that Chrysler has not done a recall on these wire harnesses.  FURTHER your detail on the voltage for each triggered his find as well....I just got back from bringing him some but connectors and wire looms...Now he is in the process of cutting out the bad spots, splicing, re-wrapping etc. AND putting wires back together in the dash area. MANY MANY MANY THANKs AND GRATITUDE FOR YOUR PERSISTENCE AND EXPERT 'SLUETHIng'  Had you NOT sent that last 'hunch' or 'by the way check this' regarding the details and specs on wires from tcm and pcm - God only knows what I would be facing right now!!

Answer
Hi Morgan,
I am really pleased to have helped you and Brian find out why that strange behavior with the code reader being needed to get the engine to start. Was there a reason for the harness getting melted, such as it being to near the exhaust system? I will keep this experience in mind for future no starts without explanation.
Roland