wiring CHRYSLER CARAVAN 2000 Service Manual

3.3.2 Intermittent Code
A diagnostic trouble code that is not there every time the engine control module/SKIM checks the
circuit is an ªintermittentº code. Most intermittent codes are caused by wiring or connector
problems. Defects that come and go like this are the most difficult to diagnose; they must be
looked for under specific conditions that cause them. The following checks may assist you in
identifying a possible intermittent problem:
²Visually inspect related wire harness connectors. Look for broken, bent, pushed out, or
corroded terminals.
²Visually inspect the related harnesses. Look for chafed, pierced, or partially broken wire.
²Refer to any hotlines or technical service bulletins that may apply.
NOTE: Electromagnetic (radio) interference can cause an intermittent system malfunction. This
interference can interrupt communication between the ignition key transponder and the SKIM.
3.3.3 Reset Counter
The reset counter counts the number of times the vehicle has been started since codes were last
set, erased, or the battery was disconnected. The reset counter will count up to 255 start counts.
The number of starts helps determine when the trouble code actually happened. This is recorded
by the ECM and can be viewed on the DRB as the RESET COUNTER.
When there are no trouble codes stored in memory, the DRB will display ªNO TROUBLE CODES
FOUNDº and the reset counter will show ªRESET COUNT = XXX.º
3.3.4 ECM Diagnostic Trouble Codes
A/C CONTROL SHORT CIRCUIT
A/C CONTROL OPEN CIRCUIT
A/C SYSTEM PRESSURE SIGNAL HIGH EXCEEDED
A/C SYSTEM PRESSURE SIGNAL LOW EXCEEDED
A/C SYSTEM PRESSURE SUPPLY HIGH EXCEEDED
A/C SYSTEM PRESSURE SUPPLY LOW EXCEEDED
ACCELERATOR PEDAL SENSOR SIGNAL HIGH EXCEEDED
ACCELERATOR PEDAL SENSOR PLAUSIBILITY
ACCELERATOR PEDAL SENSOR PWG PLAUS WITH LOW IDLE SWITCH
ACCELERATOR PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER
ATMOSPHERIC PRESSURE SENSOR SRC HIGH EXCEEDED
ATMOSPHERIC PRESSURE SENSOR SRC LOW EXCEEDED
BATTERY VOLTAGE SRC HIGH EXCEEDED
BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT
CLUTCH SIGNAL PLAUSIBILITY
CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED
CONTROL SLEEVE SENSOR START END POS. NOT ATTAINED
CONTROL SLEEVE SENSOR STOP END POS. NOT ATTAINED
CRUISE STATUS INDICATOR LAMP SHORT CIRCUIT
DIAGNOSTIC LAMP OPEN CIRCUIT
DIAGNOSTIC LAMP SHORT CIRCUIT
DIESEL POWER RELAY SHUTS OFF TOO EARLY
DIESEL POWER RELAY SHUTS OFF TOO LATE
EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ. (EGR)
EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212
EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM
EEPROM PLAUSIBILITY FUNC. SWITCH WRONG OR MISSING
EEPROM PLAUSIBILITY VER. NUMBER NOT CORRESPONDING
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3.5.1 DRB Does Not Power Up
If the LED's do not light or no sound is emitted at start up, check for loose cable connections or
a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11
volts at DLC cavity 16 is required to adequately power the DRB. Check for proper ground
connection at DLC cavities 4 and 5.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. For
a blank screen, refer to the appropriate diagnostics manual.
3.5.2 Display is Not Visible
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
condition.
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TEST TC-1ACONTINUED - REPAIRING - A/C CONTROL SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-1A TURN IGNITION ON.
CONTINUED FROM IS THE A/C CLUTCH NO CONTINUE TEST
THE PREVIOUS WITH THE DRB, RELAY CLICKING? TC-1A ON THE
PAGE. ACTUATE THE A/C NEXT PAGE.
CLUTCH RELAY.
YES
THE CONDITION TO SET USING THE SCHEMATIC
THE TROUBLE CODE IS AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
NOT PRESENT. THE WIRING AND FOUND? NECESSARY.*
CONNECTORS.
FIG.1 FIG.2
NO
WIGGLE THE WIRING NOTE: THE DRB MUST REPAIR AS
HARNESS FROM THE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
RELAY TO THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
ENGINE CONTROL RELAY. CLICKING? CLICKING TO BE
MODULE.INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-2ACONTINUED - REPAIRING - A/C CONTROL OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-2A TURN IGNITION ON.
CONTINUED FROM IS THE A/C CLUTCH NO CONTINUE TEST
THE PREVIOUS WITH THE DRB, RELAY CLICKING? TC-2A ON THE
PAGE. ACTUATE THE A/C NEXT PAGE.
CLUTCH RELAY.
YES
THE CONDITION TO SET USING THE SCHEMATIC
THE TROUBLE CODE IS AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
NOT PRESENT. THE WIRING AND FOUND? NECESSARY.*
CONNECTORS.
FIG.1 FIG.2
NO
WIGGLE THE WIRING NOTE: THE DRB MUST REPAIR AS
HARNESS FROM THE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
RELAY TO THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
ENGINE CONTROL RELAY. CLICKING? CLICKING TO BE
MODULE.INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-3AREPAIRING - A/C SYSTEM PRESSURE SIGNAL HIGH EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN A/C ON.
START TEST WITH THE DRB, READ IS THE A/C OUTPUT YES CONTINUE TEST
TC-3A. THE A/C OUTPUT VOLTAGE ABOVE TC-3A ON THE
VOLTAGE. 4.8 VOLTS? NEXT PAGE.
NO
USE THE SCHEMATIC AS REPAIR THE HARNESS
A GUIDE AND WIGGLE MONITOR THE DRB WAS THERE ANY A/C YES OR CONNECTOR THAT
A/C PRESSURE SENSOR DISPLAY. OUTPUT VOLTAGE CAUSED THE VOLTAGE
CONNECTOR & HARNESS. CHANGE? CHANGE.*
FIG.1
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
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-4AREPAIRING - A/C SYSTEM PRESSURE SIGNAL LOW EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN A/C ON.
START TEST WITH THE DRB, READ IS THE A/C OUTPUT YES CONTINUE TEST
TC-4A. THE A/C OUTPUT VOLTAGE BELOW 0.2 TC-4A ON THE
VOLTAGE. VOLT? NEXT PAGE.
NO
USE THE SCHEMATIC AS REPAIR THE HARNESS
A GUIDE AND WIGGLE MONITOR THE DRB WAS THERE ANY A/C YES OR CONNECTOR THAT
A/C PRESSURE SENSOR DISPLAY. OUTPUT VOLTAGE CAUSED THE VOLTAGE
CONNECTOR & HARNESS. CHANGE? CHANGE.*
FIG.1
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
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-5AREPAIRING - A/C SYSTEM PRESSURE SUPPLY HIGH EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION ON. DOES THE DRB
START TEST WITH THE DRB, DISPLAY "A/C YES CONTINUE TEST
TC-5A. ERASE CODES. SYSTEM PRESSURE TC-5A ON THE
SUPPLY HIGH NEXT PAGE.
TURN A/C ON. EXCEEDED"?
NO
WIGGLE THE A/C DOES THE DRB REPAIR THE
PRESSURE SENSOR MONITOR THE DRB DISPLAY "A/C YES CONNECTOR OR
CONNECTOR AND DISPLAY. SYSTEM PRESSURE HARNESS WIRES THAT
HARNESS WIRES. SUPPLY HIGH"? CAUSED THE CODE TO
SET.*
NO
AT THIS TIME THE USING THE
CONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
TO SET THIS CODE GUIDE, INSPECT THE FOUND? NECESSARY.*
IS NOT PRESENT. WIRING AND
CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES. FIG.1
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TEST TC-6AREPAIRING - A/C SYSTEM PRESSURE SUPPLY LOW EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION ON. DOES THE DRB
START TEST WITH THE DRB, DISPLAY "A/C YES CONTINUE TEST
TC-6A. ERASE CODES. SYSTEM PRESSURE TC-6A ON THE
SUPPLY LOW NEXT PAGE.
TURN A/C ON. EXCEEDED"?
NO
WIGGLE THE A/C DOES THE DRB REPAIR THE
PRESSURE SENSOR MONITOR THE DRB DISPLAY "A/C YES CONNECTOR OR
CONNECTOR AND DISPLAY. SYSTEM PRESSURE HARNESS WIRES THAT
HARNESS WIRES. SUPPLY LOW CAUSED THE CODE TO
EXCEEDED"? SET.*
NO
AT THIS TIME THE USING THE
CONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
TO SET THIS CODE GUIDE, INSPECT THE FOUND? NECESSARY.*
IS NOT PRESENT. WIRING AND
CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES. FIG.1
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TEST TC-7ACONTINUED - REPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE CODES
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-7A FULLY DPRESS THE
CONTINUED FROM THROTTLE. IS THE VOLTAGE NO REPLACE THE
THE PREVIOUS BETWEEN ACCELERATOR PEDAL
PAGE. WITH THE DRB, READ 4.1 AND 4.6 VOLTS? POSITION SENSOR.*
ACCEL PEDAL VOLTS.
YES
USING AN ANALOG SLOWLY DEPRESS AND
VOLTMETER, BACKPROBE RELEASE THE
ACCEL PEDAL SENSOR ACCELERATOR PEDAL
HARNESS CONN SEVERAL TIMES WHILE
CAVITY 7. FIG.1 OBSERVING THE METER.
NOTE: THE WITHOUT ANY SHARP DOES VOLTAGE
VOLTMETER NEEDLE INCREASE OR INCREASE AND NO REPLACE THE
SHOULD RESPOND DECREASE IN DECREASE SMOOTHLY ACCELERATOR PEDAL
SMOOTHLY TO ACCEL VOLTAGE. WITH ACCEL PEDAL POSITION SENSOR.*
PEDAL TRAVEL... TRAVEL?
YES
USING THE DRB WITH THE ACCEL PEDAL
CUSTOM DISPLAY, AND THE LOW IDLE AT FULL REST (IDLE) THE ACCEL PEDAL %
OBSERVE THE ACCEL SWITCH INPUT. SLOWLY DEPRESS THE AND THE LOW IDLE
PEDAL SENSOR ACCEL PEDAL WHILE SWITCH INPUT.
PERCENTAGE (%)... OBSERVING...
NOTE: THE LOW IDLE DID LOW IDLE
SWITCH INPUT BETWEEN 8% AND 21% SWITCH INPUT NO REPLACE THE
SHOULD SWITCH FROM OF ACCEL PEDAL CHANGE BETWEEN 8% ACCELERATORE PEDAL
"IDLE" TO POSITION TRAVEL. AND 21% OF ACCEL POSITION SENSOR
"ABOVE IDLE"... PEDAL TRAVEL?
YES
KEY OFF. INSPECT CONNECTOR
DISCONNECT ACCEL FOR DAMAGE, WERE ANY OF THESE YES REPAIR AS
PEDAL SENSOR AND CORROSION, CONDITIONS NECESSARY.*
ECM HARNESS TERMINAL PUSH-OUT PRESENT?
CONNECTORS. OR OTHER PROBLEMS.
NO
RECONNECT ALL WIGGLE THE WIRING REPAIR AS
CONNECTORS. AND CONNECTORS DOES THE DRB YES NECESSARY WHERE
KEY ON. ASSOCIATED WITH THE DISPLAY THIS CODE? WIGGLING CAUSED
USING THE DRB, CLEAR ACCEL PEDAL SENSOR. TROUBLE CODE TO
TROUBLE CODES. CHECK TROUBLE CODES. SET.
NO
CONTINUE TEST
TC-7A ON THE
NEXT PAGE.
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TEST TC-14AREPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
INCREASE ENGINE REPAIR CHARGING
START TEST SPEED TO 2000 RPM. IS THE VOLTAGE YES SYSTEM FOR
TC-14A. MEASURE THE ABOVE 17.0 VOLTS? OVERCHARGING
VOLTAGE AT THE CONDITION.*
BATTERY.
NO
NOTE: PERFORM THE USE THE SCHEMATIC AS REPAIR CHARGING
FOLLOWING STEP A GUIDE AND WIGGLE IS THE VOLTAGE YES SYSTEM FOR
WITH THE ENGINE THE ALTERNATOR ABOVE 17.0 VOLTS? OVERCHARGING
SPEED AT 2000 RPM. CONNECTOR & HARNESS. CONDITION.*
NO
USING THE DRB,
ERASE CODES. RUN USING THE DRB, DOES THE DRB YES REPLACE THE ENGINE
THE ENGINE AT IDLE READ CODES. DISPLAY "BATTERY CONTROL MODULE.*
AND 2500 RPM FOR VOLTAGE HIGH"?
SEVERAL MINUTES.
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.1 CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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