check engine CHRYSLER CARAVAN 2000 Service Manual

TEST NTC-2ACHECKING GLOW PLUG OPERATION
Perform TEST NTC-1A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
THE 2.5L DIESEL GLOW PLUG RELAY #1 GLOW PLUG RELAY #2
START TEST ENGINE UTILIZES SUPPLIES POWER TO SUPPLIES POWER TO
NTC-2A. TWO GLOW PLUG THE GLOW PLUGS IN THE GLOW PLUGS IN
RELAYS... CYLINDERS #1 & #4. CYLINDERS #2 & #3.
PERFORM THIS TEST
ON GLOW PLUG RELAY
#1 THEN REPEAT TURN IGNITION OFF.
TEST FOR GLOW PLUG
RELAY #2.
DISCONNECT EACH KEY ON. USING THE
GLOW PLUG HARNESS DRB, ACTUATE THE
CONNECTOR. GLOW PLUG RELAY.
USING A TEST
LIGHT, PROBE THE DOES THE TEST NO TEST NTC-2A
APPROPRIATE GLOW LIGHT FLASH ON AND CONTINUED ON
PLUG HARNESS CONN. OFF? THE NEXT PAGE.
FIG.1 AND 2
YES
GLOW PLUG CIRCUITRY
OK. REFER TO SERVICE
MANUAL TO CHECK GLOW TEST COMPLETE.*
PLUG OPERATION.
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
325
ProCarManuals.com

TEST NTC-5ACHECKING ENGINE COOLANT SENSOR CALIBRATION AND RADIATOR FAN
OPERATION
Perform TEST NTC-1A Before ProceedingN
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
332
ProCarManuals.com

TEST NTC-5ACHECKING ENGINE COOLANT SENSOR CALIBRATION AND RADIATOR FAN
OPERATION
Perform TEST NTC-1A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: USE A TEMPERA-
TURE PROBE TO ENSURE
ENGINE TEMPERATURE
IS ACTUALLY BELOW
70*C (160*F).
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
333
ProCarManuals.com

TEST NTC-7ACHECKING BOOST PRESSURE SENSOR CALIBRATION
Perform TEST NTC-1A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST TURN IGNITION ON,
NTC-7A. ENGINE OFF.
USING THE DRB, IS THE VOLTAGE
READ BOOST BETWEEN NO REPLACE THE BOOST
PRESSURE SENSOR 1.7 AND 1.95 PRESSURE SENSOR.*
VOLTAGE. VOLTS?
YES
BOOST PRESSURE
SENSOR OPERATING
NORMALLY.
TEST PASSED.
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
337
ProCarManuals.com

TEST NTC-8ACHECKING FUEL TEMPERATURE SENSOR CALIBRATION
Perform TEST NTC-1A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON, ENGINE START AND IDLE THE
START TEST OFF. USING THE ENGINE UNTIL
NTC-8A. DRB, MONITOR THE ENGINE TEMPERATURE
ECT SENSOR INPUT. REACHES 70*C
(160*F).
NOTE: IF ENGINE TEMP USING THE DRB, IS THE FUEL
IS ABOVE 70*C READ THE FUEL TEMPERATURE NO REPLACE THE FUEL
(160*F), ALLOW THE TEMPERATURE SENSOR BETWEEN INJECTION PUMP
ENGINE TO COOL DOWN INPUT. 20*C (70*F) AND ASSEMBLY.*
TO 70*C (160*F). 50*C (120*F)?
YES
COMPARE THE ECT START THE ENGINE DOES THE FUEL TEMP
AND FUEL AND ALLOW IT TO SENSOR READING NO REPLACE THE FUEL
TEMPERATURE SENSOR REACH OPERATING INCREASE STEADILY INJECTION PUMP
INPUTS IN THE TEMPERATURE OF TO 38-60*C ASSEMBLY.*
FOLLOWING STEP. 80*C (195*F). (100-140*F)?
YES
FUEL
TEMPERATURE
SENSOR OPERATING
NORMALLY.
TEST PASSED.
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
339
ProCarManuals.com

TEST NTC-9ACHECKING EGR SYSTEM
Perform TEST NTC-1A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START THE ENGINE.
INSTALL THE DRB
AND ACTUATE THE
EGR SOLENOID FOR
2 MINUTES.
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
341
ProCarManuals.com

TEST NTC-12ACHECKING THE ENGINE MECHANICAL SYSTEMS
Perform TEST NTC-1A Before Proceeding
NOTES
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
366
ProCarManuals.com

TEST NTC-12ACHECKING THE ENGINE MECHANICAL SYSTEMS
Perform TEST NTC-1A Before Proceeding
At this point in the diagnostic test procedure, you have determined that all of theengine electrical
systemsare operating as designed; therefore, theyare not the cause of the driveability problem.
The following additional items should be checked as possible mechanical causes of the problem.
1. ENGINE VALVE TIMING- must be within specifications
2. ENGINE COMPRESSION- must be within specifications
3. CAMSHAFT LOBES- check for abnormal wear
4. ENGINE SPEED SENSOR PICK-UP- check flywheel slots for debris/deterioration
5. ENGINE EXHAUST SYSTEM- must be free of any restrictions
6. ENGINE DRIVE SPROCKET- must be properly positioned
7. POWER BRAKE BOOSTER- no internal vacuum leaks
8. FUEL- must be free of contamination
9. FUEL INJECTOR- plugged or restricted injector
10. FUEL INJECTION PUMP- must be properly timed
NOTE:Always look for any Technical Service Bulletins that may relate to the problem.
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
367
ProCarManuals.com

TEST NTC-13ACONTINUED - CHECKING THE TURBOCHARGER OPERATION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST NTC-13A DISCONNECT THE AIR CONNECT AN AIR
CONTINUED FROM PRESSURE REGULATOR PRESSURE GAUGE
THE PREVIOUS AND SHOP AIR INLINE WITH THE
PAGE. SUPPLY. ACTUATOR SUPPLY
HOSE. FIG. 1
NOTE: AIR PRESSURE NOTE: VEHICLE MUST FAILURE TO DRIVE WITH THE VEHICLE IN
GAUGE MUST BE BE ON FLAT LEVEL VEHICLE ON LEVEL FIRST GEAR, INCREASE
RATED TO AT LEAST ROAD TO PERFORM ROAD COULD RESULT ENGINE SPEED TO RPM
50 PSI. THE FOLLOWINGS IN INCORRECT BOOST INDICATED IN
STEPS. PRESSURE READINGS. FIGURE 2.
MAINTAIN EACH RECORD BOOST
INDICATED ENGINE RPM PRESSURE AT ALL
FOR SEVERAL SECONDS INDICATED ENGINE
UNTIL BOOST PRESSURE SPEEDS.
STABILIZES. FIG. 2
DO RECORDED
REPEAT PREVIOUS READINGS MATCH NO REPLACE THE
STEP FOR SECOND CHART READINGS TURBOCHARGER
GEAR. +OR- 2PSI FOR EACH ASSEMBLY.
GEAR INDICATED?
YES
TURBOCHARGER OK,
TEST PASSED.
N
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
371
ProCarManuals.com

TEST SC-1ACONTINUED - CHECKING SPEED CONTROL OPERATION
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
TEST SC-1A
CONTINUED FROM
THE PREVIOUS TURN IGNITION OFF.
PAGE.
USING THE SCHEMATIC
AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
THE WIRING AND FOUND? NECESSARY.*
CONNECTORS.
FIG.1
NO
CHECK THE BRAKE LAMP ARE THE BRAKE LAMP
SWITCH AND CLUTCH SWITCH AND CLUTCH NO ADJUST OR REPLACE
PEDAL SWITCH PEDAL SWITCH AS NECESSARY.*
ADJUSTMENTS. ADJUSTED CORRECTLY?
YES
REPLACE THE ENGINE
CONTROL MODULE.*
S
P
E
E
D
C
O
N
T
R
O
L
T
E
S
T
S
375
ProCarManuals.com