battery CHRYSLER CARAVAN 2000 User Guide

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 SK-1BSKIM COMMUNICATION
Perform TEST SK-1A Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
USING THE DRB, REFER TO "BODY
START TEST ATTEMPT TO CAN YOU NO DIAGNOSTIC
SK-1B. COMMUNICATE WITH COMMUNICATE WITH PROCEDURES" MANUAL A
THE BODY CONTROL THE BCM? TO DIAGNOSE VEHICLE
MODULE. COMMUNICATION.
YES
TURN IGNITION OFF. USING AN OHMMETER,
DISCONNECT THE MEASURE BETWEEN IS THE RESISTANCE NO REPAIR THE OPEN
SKIM HARNESS GROUND AN SKIM BELOW 5.0 OHMS? GROUND CIRCUIT.*
CONNECTOR.** HARNESS CONNECTOR
CAVITY 2. FIG.1
YES
USING A VOLTMETER,
MEASURE THE BATTERY IS THE VOLTAGE NO REPAIR THE OPEN
SUPPLY CIRCUIT. ABOVE 10.0 VOLTS? BATTERY SUPPLY
CIRCUIT.*
FIG.1
YES
USING A VOLTMETER,
MEASURE THE IGNITION IS THE VOLTAGE NO REPAIR THE OPEN
TURN IGNITION ON. SUPPLY CIRCUIT. ABOVE 10.0 VOLTS? IGNITION SUPPLY
CIRCUIT.*
FIG.1
YES
WAIT 2 MINUTES MEASURE BOTH CCD IS THE VOLTAGE
BEFORE CONTINUING. BUS CIRCUITS AT BETWEEN 2.3 AND NO REPAIR THE OPEN
THE SKIM HARNESS 2.6 VOLTS FOR BOTH CCD BUS
WITH THE IGNITION CONNECTOR. MEASUREMENTS? CIRCUIT(S).*
STILL ON... FIG.1
YES
TURN IGNITION OFF. KEY ON.
CAN YOU NO REPLACE THE SENTRY
RECONNECT THE SKIM ATTEMPT TO COMMUNICATE WITH KEY IMMOBILIZER
HARNESS CONNECTOR. COMMUNICATE WITH THE SKIM? MODULE.*
THE SKIM.
YES
TEST COMPLETE.*
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TEST NTC-4ACHECKING THE PCM POWER AND GROUNDS
Perform TEST NTC-1A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: THE BATTERY
START TEST MUST BE FULLY
NTC-4A. CHARGED TO PERFORM
THIS TEST.
TURN IGNITION OFF. WITH AN OHMMETER,
DISCONNECT THE ECM MEASURE ECM IS THE RESISTANCE NO REPAIR THE OPEN
HARNESS HARNESS CONNECTOR BELOW 5.0 OHMS FOR GROUND CIRCUIT.*
CONNECTORS.** CAVITIES 1 AND 27 ALL MEASUREMENTS?
TO GROUND. FIG.1
YES
PROBE DIESEL POWER
USE A TEST LIGHT RELAY CONNECTOR DOES THE TEST NO REPAIR OPEN
IN THE FOLLOWING CAVITY (PDC) 3(30). LIGHT ILLUMINATE BATTERY SUPPLY TO
STEPS. BRIGHTLY? RELAY.
FIG.2
YES
REMOVE THE DIESEL 3(30) AND 5(87). DOES THE TEST
POWER RELAY. CONNECT WITH A TEST LIGHT, LIGHT ILLUMINATE NO REPAIR OPEN DIESEL
A JUMPER WIRE ACROSS PROBE ECM HARNESS BRIGHTLY FOR EACH POWER RELAY OUTPUT
RELAY CONNECTOR CONNECTOR CAVITIES CAVITY? CIRCUIT.*
(PDC) CAVITIES... 2 AND 28. FIG.2
YES
WITH A TEST LIGHT,
PROBE ECM HARNESS DOES THE TEST NO REPAIR THE OPEN
TURN IGNITION ON. CONNECTOR CAVITY 47. LIGHT ILLUMINATE FUSED IGNITION
BRIGHTLY? SWITCH CIRCUIT.*
FIG.1
YES
ECM GROUND
AND POWER
CIRCUITS ARE
OK. TEST
PASSED.
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TEST NTC-11BCONTINUED - CHECKING RADIATOR FAN OPERATION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST NTC-11B
CONTINUED FROM
THE PREVIOUS TURN IGNITION OFF.
PAGE.
TURN IGNITION ON. REPAIR THE OPEN
DISCONNECT RAD FAN USING A VOLTMETER, IS THE VOLTAGE NO FUSED BATTERY SUPPLY
RELAY #3.** MEASURE RELAY ABOVE 10.0 VOLTS? CKT. IF THE FUSE IS
HARNESS CONNECTOR BLOWN, CHECK FOR
CAVITY 8. FIG.1 SHORT TO GROUND.*
YES
CONNECT A JUMPER CAVITIES 2 AND 8.
WIRE ACROSS RAD IS THE RIGHT SIDE NO REPAIR OPEN RAD
FAN RELAY #3 RAD FAN ON? FAN RELAY #3
HARNESSOUTPUT CIRCUIT.*
CONNECTOR... FIG.1
YES
DISCONNECT RAD FAN RAD FAN RLY #1
RELAY #1 AND #3 HARNESS CONN. CAVITY IS THE RESISTANCE NO REPAIR OPEN HIGH
HARNESS CONNECTORS. 6 AND RAD FAN RLY #3 BELOW 5.0 OHMS? SPEED FAN CONTROL
MEASURE RESISTANCE HARNESS CONN. CAVITY CIRCUIT.*
BETWEEN... 6. FIG.1 AND 2
YES
MEASURE RESISTANCE RAD FAN RELAY #3
BETWEEN RAD FAN HARNESS CONNECTOR IS THE RESISTANCE NO REPAIR THE OPEN
RELAY #1 HARNESS CAVITY 4. BELOW 5.0 OHMS? DIESEL POWER RELAY
CONNECTOR CAVITY 4OUTPUT CIRCUIT.*
AND... FIG.1
YES
REPLACE THE RAD
FAN RELAY #3.*
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TEST NTC-11CCHECKING RADIATOR FAN OPERATION
Perform TEST NTC-11A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST
NTC-11C. TURN IGNITION OFF.
USING A VOLTMETER,
DISCONNECT THE RAD MEASURE RAD FAN IS THE VOLTAGE NO REPAIR OPEN
FAN RELAY #2.** RELAY #2 HARNESS ABOVE 11.0 VOLTS? BATTERY SUPPLY
CONNECTOR CAVITY 8. CIRCUIT OR FUSE.*
FIG.1
YES
CONNECT A JUMPER
WIRE ACROSS RAD CAVITIES 8 AND 2. DID THE FANS TURN YES REPLACE RAD FAN
FAN RELAY #2 ON? RELAY #2.*
HARNESS
CONNECTOR... FIG.1
NO
REPAIR RELAY #2
DID THE BATTERY YES OUTPUT CKT. FOR
SUPPLY FUSE BLOW? SHORT TO GROUND OR
SHORTED LEFT SIDE
RAD FAN MOTOR.*
NO
DISCONNECT FAN USE A VOLTMETER TO
MOTOR HARNESS MEASURE FAN MOTOR IS THE VOLTAGE NO REPAIR OPEN RELAY
CONNECTOR.** HARNESS CONNECTOR ABOVE 10.0 VOLTS? #2 OUTPUT
WITH JUMPER STILL CAVITY 4. CIRCUIT.*
CONNECTED... FIG.2
YES
RECONNECT FAN CONNECT A JUMPER REPAIR OPEN CKT
MOTOR HARNESS WIRE BETWEEN GROUND DID LEFT SIDE RAD NO BETWEEN RLY #1 AND
CONNECTOR. AND RAD FAN RELAY #1 FAN TURN ON? LEFT SIDE FAN MTR.*
DISCONNECT RAD FAN HARNESS CONNECTOR IF OK, REPLACE LEFT
RELAY #1.** CAVITY 8. FIG.3 SIDE FAN MTR.
YES
CONTINUE TEST
NTC-11C ON THE
NEXT PAGE.
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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 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-1ACONTINUED - REPAIRING A NO CRANK CONDITION
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
TEST NS-1A KEY OFF. WITH AN IS THE RESISTANCE
CONTINUED FROM OHMMETER, MEASURE BETWEEN NO REPLACE THE
THE PREVIOUS THE STARTER RELAY 60.0 AND 90.0 STARTER RELAY.*
PAGE. TERMINALS 85 AND 86. OHMS?
FIG.1
YES
KEY ON. USING A AT THE ECM HARNESS REPAIR THE STARTER
VOLTMETER, MEASURE CONNECTOR. IS THE VOLTAGE YES RELAY CONTROL CKT
STARTER RELAY ABOVE 1.0 VOLT? FOR A SHORT TO
CONTROL CKT... VOLTAGE.*
FIG.2
NO
WITH AN OHMMETER, BETWEEN THE ECM
MEASURE RESISTANCE HARNESS CONNECTOR IS THE RESISTANCE YES REPAIR THE OPEN
OF THE STARTER AND THE PDC ABOVE 5.0 OHMS? STARTER RELAY
RELAY CONTROLCONTROL CIRCUIT.*
CIRCUIT... FIG.2
NO
KEY ON. USING A WITH THE CLUTCH
VOLTMETER, MEASURE WHILE DEPRESSING DEPRESSED, IS THE YES REPLACE THE
THE CLUTCH THE CLUTCH. VOLTAGE ABOVE 10.0 STARTER RELAY.*
INTERLOCK SWITCH VOLTS?
CKT AT THE PDC)...
NO
KEY OFF. DISCONNECT MEASURE CLUTCH
THE CLUTCH INTERLOCK INTERLOCK SWITCH IS THE VOLTAGE NO REPAIR OPEN CLUTCH
SWITCH HARNESS HARNESS CONNECTOR ABOVE 10.0 VOLTS? INTERLOCK SWITCH
CONNECTOR. KEY ON. CAVITY 1. BATTERY SUPPLY.*
USING A VOLTMETER... FIG.3
YES
CONNECT A JUMPER PROBE THE CLUTCH
WIRE ACROSS THE INTERLOCK SWITCH IS THE VOLTAGE YES ADJUST OR REPLACE
CLUTCH INTERLOCK OUTPUT CKT. IN THE ABOVE 10.0 VOLTS? THE CLUTCH
SWITCH HARNESS PDC. INTERLOCK SWITCH.*
CONNECTOR. FIG.2
NO
REPAIR OPEN
CIRCUIT BETWEEN
STARTER RELAY AND
CLUTCH INTERLOCK
SWITCH.*
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