Need advice. My 2006 DodgeCaravan started shaking profusely on startup and also when accelerating. If we baby it and pop it into neutral it calms down some.We did a test and got the P0204 code. We took it to our mechanic and he is telling us he tested the PCM and it needs replaced. Before taking it to him we noticed that some of the wiring to the fuel injectors/spark plugs were completely bare copper wire. We did tape them up but could not see all the wiring deeper down so I asked him to check it. My mechanic is saying he doesnt feel that has anything to do with the PCM going. Is it possible this is a wiring issue? Should we go by this "test" he did to the PCM? Im just not too convinced this is the problem.

 

This is getting to be a far too common problem on these vans. That wire harness is a Chrysler design flaw many are paying for. It was routed too close to the exhaust manifold and not protected from the heat to the degree needed.

Could it be your problem? Sure could but if the mechanic verified the wiring to the #4 injector has continuity from the injector to the PCM and nothing else then the wiring likely is not the problem. Bare wire doesn't become a problem until it touches something conductive and/or breaks. Course you have to repair it before it does that.

He may have had a capable scanner to do all his testing. Us DIYers would either feel the injector for a click or listen with a screw driver to the ear. If there was no click you would then check electrically using a test or noid light. If the light didn't flash indicating a pulse from the PCM then, using a multimeter, you would verify wiring continuity from the PCM to the injector. If that was good then you order a new PCM. His scanner may have verified all that in seconds.

Putting his confidence and your concerns together you could try this. Tell him if the PCM proves not to be the problem you won't pay for it.

PCMs have an 8 year 80K mile EPA warranty. If it is the PCM, you may get it free. If not they can be had for $300 and in some cases less.

 

The output drivers on the PCM are sensitive at best. If you have grounded the output to the injectors (bare wires) the odds are you have cooked the PCM.

 

and of course, if you do no fix the wire, you will just fry the New PCM you are about to install. Just fix the wires the right way, and see if problem still exist, if it does, you probably need a PCM.
A Reman PCM from computer exchange website is not that expensive.
Of course, if you are under waranty, then it would be free.

 

Fix the wiring problem first if the harness is melted together, Because if you don't you will fry the new or reman PCM in no time. Just like steak59 had said.

 

Thank you very much to all of you. I have to apologize but my husband and I dont know much about electrical systems and I am just trying to find out how to make sure this problem is taken care of correctly. My main concern of course is that I would replace the PCM and possibly fry that one due to the bad wires. We had to replace my engine at 57,000 miles (which I tried to fight with Dodge about) so we do not have the original engine. My mechanic told me we have to get the PCM from the dealer because they may not program a used one?? We were quoted $485 for the PCM plus $75 to install and $70 to program. Of course this does not include any wire issues. I asked the dealer the cost of new wires and he said $1095?? I dont know if he misunderstood me?? We could not see all the wires in the harness due to them being in the back so I dont know what the rest look like. Can the wires I have be fixed or should they totally be replaced? I guess Im not sure if my mechanic really spent time trying to figure out whats going on and I am trying to figure out what steps I should take first. I dont know how well he looked at those wires. I thought about taking a chance and paying $75 to have Dodge look at it but Im nervous I will get ripped off. Thank you so much!! All advice is appreciated!!

 

As the guys said, wiring first. I just assumed you would know that. The 1095 is for a new harness which is the right way to do the fix. Having said that, a good automotive electrician should be able to splice the burned out section with new wires for alot less. For now, tape up the burned areas (make sure you get them all) replace the PCM and then shop around for someone to do the wiring right.

 

yeah, $1095 is the price of the entire engine wiring loom. It is like 5 pounds of wires with all connectors. You do not need that unless the wiring damage is Extremely severe.
They don't have to be completely replaced, but they should be Soldered and Shrink wrapped. "Twist and Tape" method is good for Home, but not Automobile, because the Wires in the house never Moves, but wires in cars always moves and expose to Salt, dirts, and water.

I would recommend you to drive into the dealership, tell them about the wire and Check engine light, and pay the Diagnostic fee. Don't mention anything about suspected Bad PCM, pay the diag fee and let them figure it out and get an estimate. But telling them about the wires will save them time and your money "trying to look for the bad wire", since you alrdy know where it is.

I dont think anyone is trying to rip you off. And it appears to me your mechanic is not any cheaper than the dealership.

 

Here's a thread on another forum that talks all about this harness. It lists a new harness available for around $200, part numbers, shows how to make the repairs and several revealing pictures: http://forum.chryslerminivan.net/sho...t=wire+harness

 

Great find cougar41! I just bought my daughter a 2012 GC which is why I joined this forum. Does this issue apply to the new ones as well? I'm pretty green on the GC`s but know the LX platform very well so please excuse the newbie questions