engine CHRYSLER CARAVAN 2000 Service Manual

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.
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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.
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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.
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TEST NTC-12ACHECKING THE ENGINE MECHANICAL SYSTEMS
Perform TEST NTC-1A Before Proceeding
NOTES
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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.
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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.
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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.*
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TEST SC-2ACHECKING SPEED CONTROL OPERATION
Perform TEST SC-1A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
KEY OFF.
START TEST DISCONNECT THE
SC-2A. CLOCKSPRING
HARNESS
CONNECTOR.**
KEY ON. USING THE A JUMPER WIRE DID THE VOLTAGE
DRB, MONITOR THE ACROSS CLOCKSPRING CHANGE FROM YES REPLACE THE SPEED
CRUISE SWITCH HARNESS CONNECTOR APPROXIMATELY 5.0 CONTROL SWITCHES.*
VOLTAGE WHILE CAVITIES 3 AND 4. VOLTS TO 0 VOLTS?
CONNECTING... FIG.1
NO
KEY ON. PROBE THE REPAIR THE OPEN
USE A VOLTMETER IN CLOCKSPRING IS THE VOLTAGE YES SPEED CONTROL
THE FOLLOWING HARNESS CONNECTOR ABOVE 4.0 VOLTS? SWITCH GROUND
STEP. CAVITY 4. CIRCUIT.*
NO
KEY OFF. USING AN OHMMETER,
DISCONNECT THE ECM MEASURE THE SPEED IS THE RESISTANCE YES REPAIR THE OPEN
HARNESS CONTROL SWITCH ABOVE 5.0 OHMS? SPEED CONTROL
CONNECTORS.** CIRCUIT. SWITCH CIRCUIT.*
FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST SC-3ACONTINUED - CHECKING SPEED CONTROL OPERATION
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
TEST SC-3A KEY OFF.
CONTINUED FROM
THE PREVIOUS DISCONNECT THE BRAKE
PAGE. LAMP SWITCH HARNESS
CONNECTOR.**
USING A VOLTMETER, REPAIR THE BRAKE
PROBE BRAKE LAMP IS THE VOLTAGE NO LAMP SWITCH FUSED
SWITCH HARNESS ABOVE 9.0 VOLTS? BATTERY SUPPLY
CONNECTOR CAVITY 6. CIRCUIT FOR AN
FIG.1 OPEN.*
YES
CONNECT A JUMPER DOES THE DRB
BETWEEN BRAKE LAMP DISPLAY CHANGE YES ADJUST OR REPLACE
SWITCH HARNESS TURN IGNITION ON. FROM "RELEASED" TO THE BRAKE LAMP
CONNECTOR CAVITIES "PRESSED"? SWITCH.*
5 AND 6. FIG.1
NO
REMOVE THE JUMPER. AT THE BRAKE LAMP REPAIR THE PRIMARY
USING A VOLTMETER, SWITCH HARNESS IS THE VOLTAGE NO BRAKE SWITCH
MEASURE THE CONNECTOR CAVITY 5. BELOW 1.0 VOLT? SIGNAL CIRCUIT FOR
PRIMARY SWITCH A SHORT TO
SIGNAL CIRCUIT... FIG.1 VOLTAGE.*
YES
KEY OFF. USING AN OHMMETER, REPAIR THE PRIMARY
MEASURE RESISTANCE IS THE RESISTANCE NO BRAKE SWITCH
DISCONNECT THE ECM OF THE PRIMARY BRAKE BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
HARNESS SW SIGNAL CKT. AN OPEN.*
CONNECTORS.** FIG.2
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST SC-3BCHECKING SPEED CONTROL OPERATION
Perform TEST SC-3A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
START TEST
SC-3B. TURN IGNITION OFF.
DISCONNECT THE KEY ON. USING A
BRAKE LAMP SWITCH VOLTMETER, MEASURE IS THE VOLTAGE NO CONTINUE TEST
HARNESS VOLTAGE AT CAVITY 1. ABOVE 9.0 VOLTS? SC-3B ON THE
CONNECTOR.** NEXT PAGE.
FIG.1
YES
USING A JUMPER WHILE MONITORING DID THE DRB
WIRE, CONNECT THE DRB. DISPLAY CHANGE YES ADJUST OR REPLACE
BRAKE LAMP SWITCH FROM "PRESSED" TO THE BRAKE LAMP
CONNECTOR CAVITY 1 "RELEASED"? SWITCH.*
TO GROUND... FIG.1
NO
USING AN OHMMETER,REPAIR THE OPEN
MEASURE THE IS THE RESISTANCE YES SECONDARY BRAKE
RESISTANCE BETWEEN ABOVE 10.0 OHMS? LAMP SWITCH GROUND
CONNECTOR CAVITY 2CIRCUIT.*
AND GROUND. FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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