check engine CHRYSLER CARAVAN 2000 Service Manual

TEST TC-86AREPAIRING - TIMING GOVERNING POSITIVE GOVERNOR DEVIATION
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: INCORRECT HAS THE TIMING VERIFY CORRECT
START TEST INJECTION PUMP CHAIN, TIMING YES VALVE TIMING AND
TC-86A. TIMING CAN CAUSE GEARS OR INJECTION INJECTION PUMP
THIS TROUBLE CODE. PUMP BEEN SERVICED TIMING BEFORE
RECENTLY? CONTINUING.
NO
WITH THE DRB, ATTEMPT TO START READ CODES. DOES
ERASE CODES. ENGINE AND THE DRB DISPLAY YES CONTINUE TEST
INCREASE ENGINE "TIMING GOVERNING TC-86A ON THE
TURN IGNITION OFF SPEED ABOVE 1000 POSITIVE GOVERNOR NEXT PAGE.
FOR 10 SECONDS. RPM. DEVIATION"?
NO
USE THE SCHEMATIC AS DOES THE DRB REPAIR THE HARNESS
A GUIDE AND WIGGLE MONITOR THE DRB DISPLAY "TIMING YES OR CONNECTOR THAT
THE SENSOR CONNECTOR DISPLAY. GOVERNING POSITIVE CAUSED THE CODE TO
& HARNESS. GOVERNOR SET.*
FIG.1 DEVIATION"?
NO
AT THIS TIME, THE USING THE
CONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
TO SET THE CODE IS GUIDE, INSPECT THE FOUND? NECESSARY.*
NOT PRESENT. WIRING AND
FIG.2 CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-86ACONTINUED - REPAIRING - TIMING GOVERNING POSITIVE GOVERNOR DEVIATION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: THIS CODE
TEST TC-86A WILL SET DUE TO
CONTINUED FROM LOW FUEL VOLUME TO
PREVIOUS PAGE. THE INJECTION
PUMP.
CHECK THE FUEL WERE ANY PROBLEMS YES REPAIR AS
SYSTEM FOR FOUND? NECESSARY.*
RESTRICTIONS.
NO
TEST DRIVE THE
REPLACE THE FUEL VEHICLE. USING THE DOES THE DRB NO
INJECTION PUMP DRB, DISPLAY DISPLAY THIS CODE? TEST COMPLETED.*
ASSEMBLY.* CODES.
YES
NOTE: BEFORE
REPLACING THE ECM, DID THE FUEL YES REPLACE THE ENGINE
PERFORM TEST NTC-3A INJECTION PUMP CONTROL MODULE.*
TO CHECK INTERNAL PASS TEST NTC-3A?
FUEL PUMP CIRCUITRY.
NO
REPLACE THE FUEL
INJECTION PUMP
ASSEMBLY.*
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TEST TC-91ACONTINUED - REPAIRING - VEHICLE SPEED SENSOR TROUBLE CODES
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-91A
CONTINUED FROM IS THE VOLTAGE YES CONTINUE TEST
THE PREVIOUS ABOVE 6.0 VOLTS IN TC-91A ON THE
PAGE. THE PREVIOUS STEP? NEXT PAGE.
NO
KEY OFF. KEY ON.
USING A VOLTMETER, IS THE VOLTAGE YES REPLACE THE BODY
DISCONNECT THE BCM MEASURE THE VSS BETWEEN CONTROL MODULE.*
"B" HARNESS SIGNAL CKT. 4.0 AND 6.0 VOLTS?
CONNECTOR.** FIG.1
NO
KEY OFF. USING AN OHMMETER, REPAIR THE VSS
MEASURE BETWEEN IS THE RESISTANCE YES SIGNAL CIRCUIT FOR
DISCONNECT THE ECM VSS SIGNAL CKT AND BELOW 5.0 OHMS? A SHORT TO SENSOR
HARNESS SENSOR GROUND CKT. GROUND CIRCUIT.*
CONNECTORS.** FIG.1
NO
USING AN OHMMETER, REPAIR THE VSS
MEASURE BETWEEN IS THE RESISTANCE YES SIGNAL CIRCUIT FOR
VSS SIGNAL CKT AND BELOW 5.0 OHMS? A SHORT TO
GROUND. GROUND.*
FIG.1
NO
USING AN OHMMETER,
MEASURE THE THE VSS SENSOR AND IS THE RESISTANCE NO REPAIR THE OPEN
RESISTANCE OF THE THE ECM. BELOW 5.0 OHMS? VSS SIGNAL
VSS SIGNAL CKTCIRCUIT.*
BETWEEN... FIG.2
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-91ACONTINUED - REPAIRING - VEHICLE SPEED SENSOR TROUBLE CODES
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-91A KEY OFF.
CONTINUED FROM
THE PREVIOUS DISCONNECT THE BCM
PAGE. "B" HARNESS
CONNECTOR.**
USING A VOLTMETER,
MEASURE THE VSS IS THE VOLTAGE YES REPLACE THE BODY
TURN IGNITION ON. SIGNAL CKT. BELOW 5.0 VOLTS? CONTROL MODULE.*
FIG.1
NO
KEY OFF.
REMOVE THE DIESEL
DISCONNECT THE ECM POWER RELAY.*
HARNESS
CONNECTORS.* FIG.2
WITH A JUMPER WIRE, KEY ON. USING A REPAIR THE VSS
CONNECT DIESEL POWER VOLTMETER, MEASURE IS THE VOLTAGE NO SIGNAL CIRCUIT FOR
RELAY CONNECTOR THE VSS SIGNAL CKT. ABOVE 1.0 VOLT? A SHORT TO
CAVITIES 30 AND 87 VOLTAGE.*
(IN PDC). FIG.2 FIG.1
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-91BREPAIRING - VEHICLE SPEED SENSOR TROUBLE CODES
Perform TEST TC-91A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
USING THE DRB
START TEST RECONNECT THE VSS RAISE AND SUPPORT OSCILLOSCOPE
TC-91B. AND ECM HARNESS THE VEHICLE DRIVE FUNCTION SELECT
CONNECTORS. AXLE. "LAB SCOPE".
SET VOLTAGE RANGE USING THE
TO +10.0v. SET TIME RANGE TO OSCILLOSCOPE LEAD,
SET PROBE TO x10. 40ms/Div. BACKPROBE ECM
HARNESS CONNECTOR
FIG.1 FIG.2 CAVITY 51. FIG.3
START THE ENGINE. SHIFT TRANSMISSION
INTO FIRST GEAR
ENGAGE THE PARKING AND ALLOW THE
BRAKE. WHEELS TO ROTATE
AT IDLE SPEED.
NOTE: A VALID VSS DOES THE DRB
OBSERVE THE DRB SIGNAL WILL CYCLE DISPLAY THE 5.0 NO REPLACE THE
OSCILLOSCOPE HI TO LOW SIMILAR VOLT VSS SIGNAL VEHICLE SPEED
PATTERN. TO THE PATTERN CYCLING HI AND SENSOR.*
SHOWN IN FIGURE 2. LOW?
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-94AREPAIRING - VEHICLE THEFT ALARM TROUBLE CODES
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
CHECK SKIS MODULE
START TEST FOR PROPER ARE THERE ANY SKIS YES PERFORM TEST
TC-94A. COMMUNICATION AND PROBLEMS? SK-1A.
TROUBLE CODES
BEFORE CONTINUING.
NO
USING THE DRB,
SELECT "ENGINE"
FROM THE MAIN
MENU.
DISPLAY THE DOES THE REPLACE THE ENGINE
VEHICLE COMPARE THE PROGRAMMED VIN NO CONTROL MODULE AND
IDENTIFICATION PROGRAMMED VIN TO MATCH THE VEHICLE PROGRAM THE
NUMBER (VIN). THE VEHICLE VIN. VIN? CORRECT VIN INTO
THE ECM.*
YES
USING THE DRB,
SELECT "BODY" THEN
"BODY COMPUTER".
DISPLAY THE DOES THE REPLACE THE BODY
VEHICLE COMPARE THE PROGRAMMED VIN NO CONTROL MODULE AND
IDENTIFICATION PROGRAMMED VIN TO MATCH THE VEHICLE PROGRAM THE
NUMBER (VIN). THE VEHICLE VIN. VIN? CORRECT VIN INTO
THE BCM.*
YES
CONTINUE TEST
TC-94A ON THE
NEXT PAGE.
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TEST TC-94ACONTINUED - REPAIRING - VEHICLE THEFT ALARM TROUBLE CODES
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-94A
CONTINUED FROM
THE PREVIOUS TURN IGNITION OFF.
PAGE.
DISCONNECT THE
DISCONNECT THE ECM BODY CONTROL
HARNESS MODULE HARNESS
CONNECTORS.** CONNECTORS.**
USING AN OHMMETER, BETWEEN THE BCM
MEASURE RESISTANCE AND THE ECM. IS THE RESISTANCE YES REPAIR THE OPEN
OF THE IMMOBILIZER ABOVE 5.0 OHMS? IMMOBILIZER SIGNAL
SIGNAL CIRCUIT... CIRCUIT.*
FIG.1
NO
ENGINE CONTROL REPAIR THE
MEASURE RESISTANCE MODULE HARNESS IS THE RESISTANCE YES IMMOBILIZER SIGNAL
BETWEEN THE ... CONNECTOR CAVITY BELOW 5.0 OHMS? CIRCUIT FOR A
38 AND GROUND. SHORT TO GROUND.*
NO
WITH A JUMPER WIRE,
REMOVE THE DIESEL CONNECT DIESEL POWER
POWER RELAY.** RELAY CONN. CAVITIES
30 AND 87 (IN PDC).
FIG.2
USING A VOLTMETER, REPAIR THE
MEASURE ECM IS THE VOLTAGE YES IMMOBILIZER SIGNAL
TURN IGNITION ON. HARNESS CONNECTOR ABOVE 1.0 VOLT? CIRCUIT FOR A
CAVITY 38. SHORT TO VOLTAGE.*
FIG.1
NO
CONTINUE TEST
TC-94A ON THE
NEXT PAGE.
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TEST TC-94ACONTINUED - REPAIRING - VEHICLE THEFT ALARM TROUBLE CODES
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-94A TURN IGNITION OFF. RECONNECT ONLY THE
CONTINUED FROM ENGINE CONTROL
THE PREVIOUS INSTALL THE DIESEL MODULE HARNESS
PAGE. POWER RELAY. CONNECTORS.
KEY ON. MEASURE
USE AN AMMETER IN AMPERAGE FROM BCM IS THE AMPERAGE NO REPLACE THE ENGINE
THE FOLLOWING HARNESS CONNECTOR BETWEEN 1.0 AND CONTROL MODULE.*
STEP. CAVITY 72 TO GROUND. 1.4 MA?
FIG.1
YES
KEY ON. USING THE DRB
OSCILLOSCOPE
RECONNECT THE BODY FUNCTION, SELECT
CONTROL MODULE "LAB SCOPE".
HARNESS CONNECTORS.
SET VOLTAGE RANGE SET TIME RANGE TO
TO +20.0V. SET 0.1S/DIV.
PROBE TO X10.
FIG.2 FIG.3
KEY ON. USING NOTE: A VALID
OSCILLOSCOPE LEAD, IMMOBILIZER SIGNAL
BACKPROBE ECM WILL CYCLE HI AND
HARNESS CONNECTOR LO SIMILAR...
CAVITY 38. FIG. 1
DOES THE DRB
TO THE PATTERN DISPLAY SHOW THE YES REPLACE THE ENGINE
SHOWN IF FIGURE 3. 12 VOLT CONTROL MODULE.*
IMMOBILIZER SIGNAL
CYCLING HI AND LO?
NO
REPLACE THE BODY
CONTROL MODULE.*
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TEST SK-1AIDENTIFYING SENTRY KEY IMMOBILIZER SYSTEM PROBLEMS
NOTE:The Sentry Key Immobilizer System (SKIS) diagnosis may require usage of the customer's
additional keys to verify the cause of the system failure. In the event that the Sentry Key Immobilizer
Module (SKIM) needs replacing, all of the keys previously programmed into the SKIM's memory
must be programmed into the new SKIM.THEREFORE IT IS IMPORTANT THAT ALL OF THE
CUSTOMER'S KEYS PROGRAMMED FOR THE VEHICLE BE OBTAINED PRIOR TO BEGIN-
NING VEHICLE DIAGNOSIS.
NOTE:It is necessary to obtain the four-digit Personal Identification Number (PIN) from the
customer or the vehicle invoice. The PIN is required to perform certain SKIM tasks using the DRB.
NOTE:It is very important that the ECM/BCM is programmed with the correct Vehicle Identification
Number (VIN). Incorrect VIN programming may result in incorrect diagnosis and unnecessary
component replacement. Use the DRB to verify the correct VIN and country code are programmed
into the SKIM.
1. The battery must be fully charged for any test in this manual.
2. Attempt to start the engine. Crank for up to 10 seconds if necessary.
3. Connect the DRB to the diagnostic connector and select ``Theft Alarm'' then ``SKIM''.
If the DRB displays ``No Response''..................................perform test 1B
NOTE:If the DRB screen is blank or has a DRB error message displayed, go toGeneral
Information Section 3.5in this manual.
4. With the DRB, read and record SKIM trouble codes.
5. If diagnostic trouble code are displayed, refer to the diagnostic trouble code list on the next page
for the appropriate test.
NOTE:For all component locations, seeGeneral Information Section 4.0in this manual.
DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYED
DIAGNOSTIC TEST
ANTENNA FAILURE**
COP FAILURE**
EEPROM FAILURE**
PCM STATUS FAILURE SK-2A
INTERNAL FAULT**
RAM FAILURE**
ROLLING CODE FAILURE SK-3A
SERIAL LINK EXTERNAL FAULT SK-4A
STACK OVERFLOW FAILURE **
TRANSPONDER COMMUNICATION FAILURE SK-5A
TRANSPONDER CRC (CYCLIC REDUNDANCY CHECK)
FAILURESK-6A
TRANSPONDER ID MISMATCH SK-7A
TRANSPONDER RESPONSE MISMATCH SK-8A
VIN MISMATCHSK-9A
**These trouble codes indicate an internal SKIM fault. Using the DRB, clear SKIM trouble code(s).
Perform several key cycles, leaving the key on for a minimum of 30 seconds per cycle. Using the
DRB, read SKIM trouble codes. If the trouble code is present, replace the SKIM.
NOTE:An intermittent start and stall condition accompanied with a transponder DTC can be caused
by the presence of a non-programmed key or key programmed to another vehicle, near the SKIM
antenna (ignition halo). This can occur if the customer has a key holder (ring) that contains more
than one key equipped with a transponder chip.
After replacement of the Sentry Key Immobilizer Module (SKIM) seeGeneral Information Section 8.0
for SKIM initialization.
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TEST NTC-1ANO TROUBLE CODE TEST MENU
First, check all Technical Service Bulletins that relate to this driveability problem. Perform corrective
actions if indicated; otherwise continue.
1.NO TROUBLE CODE COMPLETE TEST(non-monitored and monitored circuits)
PerformNTC-2AthroughNTC-13Ain sequence until the driveability problem is found.
NO TROUBLE CODE MENU
CHECKING GLOW PLUG OPERATION.........................................NTC-2A
CHECKING FUEL INJECTION PUMP CIRCUITS.................................NTC-3A
CHECKING THE PCM POWER AND GROUND CIRCUITS.........................NTC-4A
CHECKING ENGINE COOLANT SENSOR CALIBRATION..........................NTC-5A
CHECKING ACCELERATOR PEDAL SENSOR CALIBRATION......................NTC-6A
CHECKING BOOST PRESSURE SENSOR CALIBRATION.........................NTC-7A
CHECKING FUEL TEMPERATURE SENSOR CALIBRATION.......................NTC-8A
CHECKING EGR SYSTEM...................................................NTC-9A
CHECKING THE FUEL HEATER.............................................NTC-10A
CHECKING RADIATOR FAN OPERATION.....................................NTC-11A
CHECKING THE ENGINE MECHANICAL SYSTEMS.............................NTC-12A
CHECKING THE TURBOCHARGER..........................................NTC-13A
2.NO TROUBLE CODE QUICK INDIVIDUAL TEST(individual test only)
If you suspect any of the above items to be the cause of the vehicle's driveability problem, perform
the associated test(s) individually.Return to No Trouble Code Menu if driveability problem still
exists, or perform No Trouble Code Complete Test.
3.NO TROUBLE CODE QUICK SYMPTOM TEST(symptom test only)
Symptom checks cannot be used properly unless the driveability problem characteristic actually
happens while the vehicle is being tested. To reduce diagnostic time, ensure that DTC TEST and
appropriate GENERAL INFORMATION sections have been reviewed before attempting to diagnose
a symptom.
Select the symptom that most accurately describes the vehicle's driveability problem and then
perform the test routine that pertains to this symptom. Perform each routine test in sequence until
the problem is found. For definitions, see Section 12.0 in the GENERAL INFORMATION section in
this manual.
NOTE:For all component locations seeGeneral Information Section 4.0in this manual.
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