engine CHRYSLER CARAVAN 2000 Service Manual

TEST SC-3BCONTINUED - CHECKING SPEED CONTROL OPERATION
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
TEST SC-3B
CONTINUED FROM DISCONNECT THE ECM
THE PREVIOUS TURN IGNITION OFF. HARNESS
PAGE. CONNECTORS.**
OF THE SECONDARY REPAIR OPEN IN THE
USING AN OHMMETER, BRAKE LAMP SWITCH IS THE RESISTANCE NO SECONDARY BRAKE
MEASURE THE SIGNAL CIRCUIT. BELOW 5.0 OHMS? LAMP SWITCH SIGNAL
RESISTANCE...CIRCUIT.*
FIG.1
YES
THE BRAKE LAMP REPAIR SHORT TO
USING AN OHMMETER, SWITCH CONNECTOR IS THE RESISTANCE YES GROUND IN THE
MEASURE RESISTANCE CAVITY 1 AND GROUND. BELOW 5.0 OHMS? SECONDARY BRAKE
BETWEEN... LAMP SWITCH SIGNAL
FIG.2 CIRCUIT.*
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST SC-4ACHECKING SPEED CONTROL OPERATION
Perform TEST SC-1A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
START TEST
SC-4A. TURN IGNITION OFF.
DISCONNECT THE USING AN OHMMETER, REPAIR OPEN IN
CLUTCH PEDAL MEASURE RESISTANCE IS THE RESISTANCE NO CLUTCH PEDAL
SWITCH HARNESS BETWEEN CLUTCH PEDAL BELOW 5.0 OHMS? SWITCH GROUND
CONNECTOR.** SW.CONNECTOR CAVITY CIRCUIT.*
2 AND GROUND. FIG.1
YES
KEY ON. WHILE THE CLUTCH PEDAL CHECK ADJUSTMENT OF
OBSERVING THE DRB, SWITCH HARNESS DID THE DRB CHANGE YES CLUTCH PEDAL SWITCH.
CONNECT A JUMPER CONNECTOR CAVITIES FROM "RELEASED" TO IF ADJUSTMENT IS OK,
WIRE ACROSS... 1 AND 2. "PRESSED"? REPLACE THE CLUTCH
FIG.1 PEDAL SWITCH.*
NO
KEY OFF. USING AN OHMMETER,
DISCONNECT THE ECM MEASURE THE IS THE RESISTANCE NO REPAIR OPEN CLUTCH
HARNESS RESISTANCE OF THE BELOW 5.0 OHMS? PEDAL SWITCH SENSE
CONNECTORS.** CLUTCH PEDAL SWITCH CIRCUIT.*
CIRCUIT. FIG.2
YES
ECM HARNESS REPAIR CLUTCH
USING AN OHMMETER CONNECTOR CAVITY IS THE RESISTANCE NO PEDAL SWITCH SENSE
MEASURE RESISTANCE 46 AND GROUND. ABOVE 5.0 OHMS? CIRCUIT FOR SHORT
BETWEEN... TO GROUND.*
FIG. 1
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST SC-5ACHECKING SPEED CONTROL OPERATION
Perform TEST SC-1A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
START TEST TEST DRIVE THE DOES THE NO REFER TO THE BODY
SC-5A. VEHICLE. SPEEDOMETER DIAGNOSTIC
OPERATE CORRECTLY. PROCEDURES MANUAL...
YES
TO DIAGNOSE
INOPERATIVE
SPEEDOMETER.
USING THE DRB,
MONITOR VEHICLE DOES THE DRB YES REPLACE THE ENGINE
SPEED WHILE TEST DISPLAY CORRECT CONTROL MODULE.*
DRIVING THE VEHICLE SPEED?
VEHICLE
NO
PERFORM TEST
TC-91A.
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TEST SC-6ACHECKING CRUISE INDICATOR OPERATION
Perform TEST SC-1A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
NOTE: PERFORM TEST
START TEST SC-1A TO VERIFY
SC-6A. PROPER CRUISE
SWITCH OPERATION
BEFORE CONTINUING.
TURN IGNITION ON. MONITOR CRUISE DOES LAMP STATE CHECK CRUISE LAMP
WITH THE DRB SELECT LAMP STATE WHILE CHANGE FROM "ON" YES BULB, REPLACE AS
"BODY" "MIC" PRESSING CRUISE TO "OFF" WHEN NECESSARY. IF OK,
"MONITOR DISPLAY" ON/OFF BUTTON PRESSING THE REPLACE THE
THEN "CCD BUS INFO". SEVERAL TIMES. BUTTON? INSTRUMENT CLUSTER.*
NO
KEY OFF. KEY ON. CONNECT A
DISCONNECT THE ECM JUMPER WIRE BETWEEN IS THE SPEED YES REPLACE THE ENGINE
HARNESS ECM HARNESS CONTROL LAMP ON? CONTROL MODULE.*
CONNECTORS.** CONNECTOR CAVITY 30
AND GROUND. FIG.1
NO
KEY OFF. USING AN OHMMETER, REPAIR SHORT TO
DISCONNECT THE BCM MEASURE RESISTANCE IS THE RESISTANCE YES GROUND ON THE
HARNESS BETWEEN ECM HARNESS BELOW 5.0 OHMS? SPEED CONTROL LAMP
CONNECTORS.** CONNECTOR CAVITY 30 CONTROL CIRCUIT.*
AND GROUND. FIG.1
NO
USING AN OHMMETER
MEASURE THE SPEED IS THE RESISTANCE YES REPAIR OPEN SPEED
CONTROL LAMP ABOVE 5.0 OHMS? CONTROL LAMP
CONTROL CIRCUIT. CONTROL CIRCUIT.*
FIG.2
NO
REPLACE THE BODY
CONTROL MODULE.*
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TEST NS-SELNO START SELECTION MENU
NOTE:The battery must be fully charged before performing any test in this manual.
NOTE:If the engine will not crank or cranks but will not run, be sure to check the Sentry Key
Immobilizer Module (SKIM) for proper communication and trouble codes.
NOTE:With the DRB, attempt to read ECM trouble codes. If the DRB is unable to communicate with
the ECM, perform test NS-2A. If there are any trouble codes present they must be repaired before
continuing with the No Start Symptom diagnostics.
Below you will find a recommended procedure to correct a No Start Problem by symptom. They
should be performed in the order that they are listed.
Repairing a No Crank Condition..............................................NS-1A
Repairing a No Response Condition...........................................NS-2A
Repairing a No Start Condition................................................NS-3A
Repairing a Start and Stall Condition...........................................NS-4A
Checking the Engine Mechanical Systems......................................NS-5A
NOTE:A failed engine coolant temperature (ECT) sensor can cause a cranks but will not run or an
extended cranking before starting condition. This occurs when the ECT sensor calibration fails
(sensor indicates engine temp is warmer than actual engine temp) and the ECM cannot command
proper fuel quantity to the injection pump.
NOTE:For all component locations seeGeneral Information Section 4.0 in this manual.
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TEST NS-1AREPAIRING A NO CRANK CONDITION
Perform TEST NS-SEL Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
NOTE: BATTERY MUST
START TEST BE FULLY CHARGED
NS-1A. BEFORE DIAGNOSING
A NO-START
CONDITION.
NOTE: BEFORE VEHICLE THEFT DIAGNOSE
CONTINUING, BE (SKIM) SYSTEM FOR ARE ANY CODES YES TROUBLE CODE
SURE TO CHECK DIAGNOSTIC TROUBLE PRESENT? BEFORE
ENGINE SYSTEM CODES. CONTINUING.]
AND...
NO
INSPECT BATTERY
CABLES FOR IS THERE EVIDENCE YES REPAIR AS
TURN IGNITION OFF. CORROSION, OF PROBLEMS? NECESSARY.*
LOOSENESS OR OTHER
PROBLEMS.
NO
TURN IGNITION OFF. KEY ON. WITH A REPAIR THE STARTER
VOLTMETER, MEASURE IS THE VOLTAGE YES RELAY CONTROL
DISCONNECT THE ECM THE STARTER RELAY ABOVE 1.0 VOLT? CIRCUIT FOR A
HARNESS CONTROL CKT. SHORT TO VOLTAGE.*
CONNECTORS.** FIG.1
NO
KEY OFF. USING A FULLY DEPRESS THE
JUMPER WIRE CONNECT CLUTCH PEDAL. DID THE ENGINE YES REPLACE THE ENGINE
THE STARTER RELAY CRANK? CONTROL MODULE.*
CONTROL CKT TO ATTEMPT TO CRANK
GROUND. FIG.1 THE ENGINE.
NO
WITH A VOLTMETER,
DISCONNECT THE MEASURE THE FUSED IS THE VOLTAGE NO REPAIR OPEN FUSED
STARTER RELAY FROM B(+) CIRCUIT. ABOVE 11.6 VOLTS? BATTERY CIRCUIT.*
THE PDC.**
FIG.1
YES
WARNING: THE TRANS WARNING: THE ENGINE BRIEFLY CONNECT A
MUST BE IN NEUTRAL MAY BE CRANKED IN JUMPER WIRE BETWEEN CONTINUE TEST
AND THE PARKING THE NEXT STEP. KEEP THE STARTER RLY NS-1A ON THE
BRAKE MUST BE ON AWAY FROM MOVING OUTPUT AND FUSED NEXT PAGE.
FOR THE NEXT STEP. ENGINE PARTS. B(+) CKTS. FIG.1
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TEST NS-1ACONTINUED - REPAIRING A NO CRANK CONDITION
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
TEST NS-1A
CONTINUED FROM DID THE STARTER YES CONTINUE TEST
THE PREVIOUS MOTOR CRANK THE NS-1A ON THE
PAGE. ENGINE? NEXT PAGE.
NO
DID THE STARTER
YES SOLENOID CLICK NO DISCONNECT THE
WHEN THE JUMPER JUMPER WIRE.
WIRE WAS
CONNECTED?
USING AN OHMMETER, DISCONNECT STARTER
MEASURE THE RELAY OUTPUT WIRE
STARTER RELAY FROM THE STARTER
OUTPUT CIRCUIT. SOLENOID.**
FIG.1 FIG.2
IS THE RESISTANCE NO REPAIR OPEN
BELOW 5.0 OHMS? STARTER RELAY
OUTPUT CKT.*
YES
CHECK THE BATTERY DID EITHER BATTERY
REINSTALL STARTER CABLES FOR HIGH CIRCUIT HAVE A YES REPAIR THE BATTERY
RELAY. RESISTANCE. (USE VOLTAGE DROP CIRCUIT FOR HIGH
SERVICE MANUAL GREATER THAN 0.2 RESISTANCE.*
PROCEDURE) VOLT?
NO
ATTEMPT TO
MANUALLY ROTATE IS THE CRANKSHAFT NO REPAIR ENGINE
THE CRANKSHAFT 360 ABLE TO ROTATE 360 MECHANICAL PROBLEM
DEGREES. DEGREES? AS NECESSARY.*
YES
REPLACE THE
STARTER MOTOR.*
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TEST NS-2AREPAIRING A NO RESPONSE CONDITION
Perform TEST NS-SEL Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
START TEST DOES THE VEHICLE YES PERFORM TEST
NS-2A. START? NS-2B.
NO
KEY OFF. WITH AN OHMMETER, IS THE RESISTANCE
MEASURE RESISTANCE ABOVE 5.0 OHMS FOR YES REPAIR THE OPEN
DISCONNECT THE ECM OF THE PCM GND CKTS ANY OF THE ECM GROUND.*
HARNESS AT HARNESS CAVITIES MEASUREMENTS?
CONNECTORS.** 1 AND 27. FIG.1
NO
KEY ON. USING A AT ECM HARNESS REPAIR OPEN OR
VOLTMETER, MEASURE CONNECTOR CAVITY 47. IS THE VOLTAGE NO SHORT TO GROUND IN
THE FUSED IGNITION ABOVE 10.0 VOLTS? THE FUSED IGNITION
SWITCH OUTPUT SWITCH OUTPUT
CIRCUIT... FIG.1 CIRCUIT.*
YES
KEY OFF. USING A VOLTMETER REPAIR OPEN FUSE
REMOVE THE DIESEL PROBE DIESEL POWER IS THE VOLTAGE NO OR FUSED BATTERY
POWER RELAY. RELAY CONNECTOR ABOVE 10.0 VOLTS? CIRCUIT TO DIESEL
CAVITY 30 (IN PDC). POWER RELAY.*
KEY ON. FIG.2
YES
KEY OFF. CONNECT A MEASURE VOLTAGE AT IS THE VOLTAGE
JUMPER WIRE ACROSS ECM HARNESS ABOVE 10.0 VOLTS NO REPAIR OPEN DIESEL
RELAY CONNECTOR CONNECTOR CAVITIES FOR EACH POWER RELAY OUTPUT
CAVATIES 30 AND 87. 2 AND 28. MEASUREMENT? CIRCUIT(S).*
FIG. 1 AND 2
YES
KEY OFF. RECONNECT WITH JUMPER WIRE
THE ENGINE CONTROL STILL CONNECTED, DOES THE VEHICLE NO REPLACE THE ENGINE
MODULE HARNESS ATTEMPT TO START START? CONTROL MODULE.*
CONNECTORS. VEHICLE.
YES
CONTINUE TEST
NS-2A ON THE
NEXT PAGE.
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TEST NS-2BCONTINUED - REPAIRING A NO RESPONSE CONDITION
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
TEST NS-2B CONNECT THE DRB TO
CONTINUED FROM A FUNCTIONAL DATA
THE PREVIOUS LINK ON ANOTHER
PAGE. VEHICLE.
REPLACE THE
WITH THE DRB, DID THE DRB NO INITIAL VEHICLE'S
TURN IGNITION ON. ATTEMPT TO READ DISPLAY "NO ENGINE CONTROL
TROUBLE CODES. RESPONSE"? MODULE.*
YES
SUBSTITUTE ANOTHER WITH THE DRB, DID THE DRB NO REPLACE THE DRB
DRB ADAPTER CABLE. ATTEMPT TO READ DISPLAY "NO ADAPTER CABLE.*
TROUBLE CODES. RESPONSE"?
YES
HAVE THE DRB
REPAIRED OR
REPLACED.*
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TEST NS-3BREPAIRING - NO START
Perform TEST NS-3A Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
START TEST
NS-3B. TURN IGNITION OFF.
DISCONNECT THE
DISCONNECT THE ECM BODY CONTROL
HARNESS MODULE HARNESS
CONNECTORS.** CONNECTORS.**
USING AN OHMMETER,
MEASURE RESISTANCE 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 ... CONNECTOR CAVITY BELOW 5.0 OHMS? CIRCUIT FOR A
38 AND GROUND. SHORT TO GROUND.*
FIG. 1
NO
USING A VOLTMETER, REPAIR THE
MEASURE VOLTAGE AT IS THE VOLTAGE YES IMMOBILIZER SIGNAL
TURN IGNITION ON. ECM HARNESS ABOVE 1.0 VOLT? CIRCUIT FOR A
CONNECTOR CAVITY 38. SHORT TO VOLTAGE.*
FIG. 1
NO
CONTINUE TEST
NS-3B ON THE
NEXT PAGE.
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