Chrysler Repair: 1990 2.5L 4 cyl. no start, throttle return spring, dodge spirit


Question
I know this is long please bear with me. My childs 1990 Dodge Spirit would not accelerate it seemed the gas pedal was stuck.  I sprayed carb cleaner into the TBI and loosened it up went for a test drive and now had a runaway car.  The plate would not quite return to closed.  I thought the small spring on the TBI may need replaced, so I removed the TBI to take the parts house to see what parts are available.  I then noticed in the parts breakdown that there is supposed to be a throttle return spring that I did not have.  I reconnected everything put on the new spring and now no start.  I had left off the Throttle Position connector.  Plug it in and still no start.  I smell fuel at the TBI.  Check for spark which is intermittent to none.  Put in new hall effects and no change so put old one back in.  Finally changed coil even though it checks the same as the old 2 ohms between posts and 9.5k from tower to post.  The car would then start  but with test drive would stall out and die past 2000 rpm.  Parked until next day.  I changed the fuel filter.  Now no start and no spark again.  At one time the coil wires showed ~5V, now if I check the posts with the key on there is 0V.  I have disconnected and reconnected the battery several times and on last try it hit for a second but did not start.

The wires, cap, rotor and spark plugs were replaced 4 months ago and the car went to AZ and back with no problems.  Currently the only trouble code showing is 27.  

Thanks for your time,

Chris


Answer
Hi Chris,
That is quite a history! You have to have spark of course, and when you turn the key to the run position it should show 12v on the + post of the coil (gray wire) for about 1 second (have a helper turn the key). Then when you start cranking the 12v should return and be there as long as you are cranking. Does that happen? If not, then I would similarly look for 12V at the dark green/black wire of the ASD relay. If you don't get that, then see if the relay is clicking for 1 second or not.
On the 27 code, that means the injector in the throttle body is not responding electrically as it is supposed to. Check for the same voltage response on the plug for the injector(dark green black wire). Then check that the white/dark blue wire on that plug is patent to pin 16 of the pcm on the left inner fender 60-way connector plug.
You have got to re-establsh spark reliably first, then you have to verify the injector is OK. Once you get spark, watch the fuel spray pattern from the injector as it is sprayed onto the throttle plate while cranking: it should be symmetrical and fine, and it should stop when you stop cranking, with no after-drip. It could be that your injector is worn out.
Check all the wires around the throttle body attached to the various plugs at the body. It gets hot there because of proximity to the exhaust manifold so you may have some wires that are shorted together due to insulation melt-through.
Let me know what you learn and we'll go on from there.
Roland