key CHRYSLER CARAVAN 2000 User Guide

TEST TC-6ACONTINUED - REPAIRING - A/C SYSTEM PRESSURE SUPPLY LOW EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-6A KEY OFF.
CONTINUED FROM DISCONNECT THE A/C
THE PREVIOUS PRESSURE SENSOR
PAGE. HARNESS
CONNECTOR.**
WITH THE DRB, IS THE A/C
MONITOR THE A/C PRESSURE SUPPLY YES REPLACE THE A/C
TURN IGNITION ON. PRESSURE SENSOR VOLTAGE ABOVE 4.0 PRESSURE SENSOR.*
SUPPLY VOLTAGE. VOLTS?
NO
KEY OFF.
DISCONNECT THE ECM USE AN OHMMETER IN
HARNESS THE FOLLOWING
CONNECTORS.** STEPS.
MEASURE THE A/C REPAIR THE A/C
PRESSURE SENSOR IS THE RESISTANCE YES PRESSURE SENSOR
5-VOLT SUPPLY BELOW 5.0 OHMS? SUPPLY CIRCUIT FOR
CIRCUIT TO GROUND. A SHORT TO
FIG.1 GROUND.*
NO
MEASURE THE A/C REPAIR THE A/C
PRESSURE SENSOR IS THE RESISTANCE YES PRESSURE SENSOR
5-VOLT SUPPLY CKT BELOW 5.0 OHMS? SUPPLY CIRCUIT FOR
TO SENSOR GROUND. A SHORT TO SENSOR
FIG.1 GROUND.*
NO
REPLACE THE ENGINE
CONTROL MODULE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
49
ProCarManuals.com

TEST TC-7AREPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE CODES
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY OFF. CONNECT ONE END OF A
START TEST JUMPER WIRE TO ACCEL
TC-7A. DISCONNECT THE ACCEL PEDAL SENSOR HARNESS
PEDAL SENSOR HARNESS CONN CAVITY 3.
CONNECTOR.** FIG.1
KEY ON. USING THE THE JUMPER WIRE TO DOES THE DRB CHANGE
DRB, READ THE ACCEL PEDAL SENSOR BETWEEN "IDLE" TO NO PERFORM TEST
"LOW IDLE SWITCH" HARNESS CONNECTOR "ABOVE IDLE" TC-7B.
INPUT WHILE TAPPING CAVITY 5. WHEN TAPPING THE
THE OTHER END OF... FIG.1 JUMPER WIRE.
YES
REMOVE JUMPER WIRE. MEASURE BETWEEN
GROUND AND THE IS THE VOLTAGE NO PERFORM TEST
USE A VOLTMETER IN 5-VOLT SUPPLY CKT. BETWEEN TC-7C.
THE FOLLOWING STEPS. 4.7 AND 5.3 VOLTS?
FIG.1
YES
MEASURE BETWEEN REPAIR THE SENSOR
SENSOR GROUND IS THE VOLTAGE NO GROUND CIRCUIT FOR
(CAV 8) AND 5-VOLT BETWEEN AN OPEN.
SUPPLY CKT. 4.7 AND 5.3 VOLTS? IF OK, REPLACE THE
FIG.1 ECM.*
YES
MEASURE BETWEEN REPAIR THE SIGNAL
GROUND AND THE IS THE VOLTAGE NO CIRCUIT FOR A
ACCEL PEDAL SENSOR BELOW 0.5 VOLT? SHORT TO VOLTAGE.
SIGNAL CKT. IF OK, REPLACE THE
FIG.1 ECM.*
YES
CONNECT A JUMPER REPAIR THE OPEN
WIRE BETWEEN THE USING THE DRB, IS THE VOLTAGE NO ACCEL PEDAL SENSOR
5-VOLT SUPPLY CKT READ THE ABOVE 4.5 VOLTS? SIGNAL CIRCUIT.
AND ACCEL PEDAL "ACCEL PEDAL VOLTS". IF OK,
SENSOR CKT. FIG.1REPLACE THE ECM.
YES
REMOVE JUMPER KEY ON. WITH THE IS THE VOLTAGE
WIRE. KEY OFF. ACCEL PEDAL AT REST BETWEEN NO REPLACE THE
RECONNECT THE (IDLE), USE THE DRB 0.28 AND 0.38 ACCELERATOR PEDAL
ACCEL PEDAL SENSOR AND READ THE ACCEL VOLTS? POSITION SENSOR.*
HARNESS CONNECTOR. PEDAL SENSOR VOLTS.
YES
CONTINUE TEST
TC-7A ON THE
NEXT PAGE.
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
51
ProCarManuals.com

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.
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
53
ProCarManuals.com

TEST TC-15ACONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-15A
CONTINUED FROM DISCONNECT THE
THE PREVIOUS PRESSURE
PAGE. SENSOR
KEY ON. USING A THE BOOST PRESSURE
VOLTMETER, MEASURE SENSOR 5-VOLT IS THE VOLTAGE NO CONTINUE TEST
THE VOLTAGE SUPPLY CIRCUIT AND ABOVE 5.2 VOLTS? TC-15A ON THE
BETWEEN... GROUND. NEXT PAGE.
FIG.1
YES
KEY OFF.
DISCONNECT THE ECM REMOVE THE DIESEL
HARNESS POWER RELAY.**
CONNECTORS.**
WITH A JUMPER WIRE, TURN IGNITION ON.
CONNECT DIESEL POWER
RELAY CONN. CAVITIES USE A VOLTMETER IN
30 AND 87 (IN PDC). THE FOLLOWING
FIG.1 STEP.
MEASURE THE 5-VOLT
SUPPLY CKT AT THE IS THE VOLTAGE YES REPAIR THE 5-VOLT
BOOST PRESSURE ABOVE 1.0 VOLT? SUPPLY CKT FOR A
SENSOR HARNESS SHORT TO VOLTAGE.*
CONNECTOR. FIG.2
NO
REPLACE THE ENGINE
CONTROL MODULE.* TURN IGNITION OFF.
BOOST
HARNESS
CONNECTOR.**
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
65
ProCarManuals.com

TEST TC-15ACONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-15A
CONTINUED FROM IS THE VOLTAGE NO CONTINUE TEST
THE PREVIOUS ABOVE 1.0 VOLT? TC-15A ON THE
PAGE.NEXT PAGE.
YES
KEY OFF.
DISCONNECT THE ECM REMOVE THE DIESEL
HARNESS POWER RELAY.**
CONNECTORS.**
WITH A JUMPER WIRE, TURN IGNITION ON.
CONNECT DIESEL POWER
RELAY CONN. CAVITIES USE A VOLTMETER IN
30 AND 87 (IN PDC). THE FOLLOWING
FIG.1 STEP.
MEASURE THE BOOST REPAIR THE BOOST
PRESSURE SENSOR IS THE VOLTAGE YES PRESSURE SENSOR
SIGNAL CIRCUIT. ABOVE 1.0 VOLT? SIGNAL CIRCUIT FOR
A SHORT TO
FIG.2 VOLTAGE.
NO
REPLACE THE ENGINE
CONTROL MODULE.* WITH A VOLTMETER,
MEASURE THE BOOST
PRESSURE SENSOR
SIGNAL CKT.
FIG.1
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
67
ProCarManuals.com

TEST TC-15ACONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-15A KEY OFF.
CONTINUED FROM
THE PREVIOUS DISCONNECT THE ECM
PAGE. HARNESS
CONNECTORS.**
USING AN OHMMETER,
MEASURE THE IS THE RESISTANCE NO REPAIR THE OPEN
RESISTANCE OF THE BELOW 5.0? SENSOR GROUND
SENSOR GROUND CKT. CIRUIT.*
FIG.1
YES
KEY ON. USING A
RECONNECT ALL VOLTMETER, BACKPROBE IS THE VOLTAGE YES REPLACE THE BOOST
CONNECTORS. ECM HARNESS ABOVE 4.5 VOLTS? PRESSURE SENSOR.*
CONNECTOR CAVITY 40.
FIG.2
NO
WITH THE DRB, READ DOES THE DRB YES REPLACE THE ENGINE
CODES. DISPLAY THIS CODE. CONTROL MODULE.*
NO
TEST COMPLETE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
69
ProCarManuals.com

TEST TC-16ACONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-16A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS BOOST PRESSURE
PAGE. SENSOR HARNESS
CONNECTOR.**
USING A VOLTMETER, REPAIR THE 5-VOLT
MEASURE THE 5-VOLT IS THE VOLTAGE NO SUPPLY CIRCUIT FOR
TURN IGNITION ON. SUPPLY CIRCUIT. ABOVE 4.9 VOLTS? AN OPEN OR SHORT
TO GROUND.*
FIG.1
YES
CONNECT A JUMPER READ THE BOOST IS THE BOOST
BETWEEN THE BOOST PRESSURE SENSOR PRESSURE SENSOR YES REPLACE THE BOOST
PRESSURE SENSOR VOLTAGE ON THE VOLTAGE ABOVE 4.5 PRESSURE SENSOR.*
SIGNAL CKT. AND THE DRB. VOLTS?
5-VOLT CKT. FIG.1
NO
TURN IGNITION OFF. USING AN OHMMETER, REPAIR THE BOOST
DISCONNECT THE ECM MEASURE THE BOOST IS THE RESISTANCE YES PRESSURE SENSOR
HARNESS PRESSURE SENSOR BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
CONNECTORS.** SIGNAL CKT TO GND. A SHORT TO
FIG.1 GROUND.*
NO
USE AN OHMMETER IN SENSOR SIGNAL REPAIR THE SENSOR
THE FOLLOWING STEP. CIRCUIT AND THE IS THE RESISTANCE YES SIGNAL CIRCUIT
TEST THE RESISTANCE SENSOR GROUND BELOW 5.0 OHMS? SHORTED TO THE
BETWEEN THE BOOST CIRCUIT. SENSOR GROUND
PRESSURE... FIG.1 CIRCUIT.*
NO
USING AN OHMMETER,
MEASURE THE BOOST IS THE RESISTANCE YES REPLACE THE ENGINE
PRESSURE SENSOR BELOW 5.0 OHMS? CONTROL MODULE.*
SIGNAL CIRCUIT.
FIG.2
NO
REPAIR THE OPEN
BOOST PRESSURE
SENSOR SIGNAL
CIRCUIT.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
73
ProCarManuals.com

TEST TC-19ACONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-19
CONTINUED FROM
THE PREVIOUS TURN IGNITION OFF.
PAGE.
DISCONNECT THE
DISCONNECT THE ECM BOOST PRESSURE
HARNESS SENSOR HARNESS
CONNECTORS.** CONNECTOR.**
MEASURE THE BOOST REPAIR THE BOOST
USE AN OHMMETER IN PRESSURE SENSOR IS THE RESISTANCE NO PRESSURE SENSOR
THE FOLLOWING SIGNAL CIRCUIT. BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
STEPS. HIGH RESISTANCE .*
FIG.1
YES
MEASURE THE BOOST REPAIR THE BOOST
PRESSURE SENSOR IS THE RESISTANCE NO PRESSURE SENSOR
GROUND CIRCUIT. BELOW 5.0 OHMS? GROUND CIRCUIT FOR
HIGH RESISTANCE.*
FIG.1
YES
MEASURE THE BOOST REPAIR THE BOOST
PRESSURE SENSOR IS THE RESISTANCE NO PRESSURE SENSOR
5-VOLT SUPPLY BELOW 5.0 OHMS? 5-VOLT SUPPLY
CIRCUIT. CIRCUIT FOR HIGH
FIG.1 RESISTANCE.*
YES
REPLACE THE BOOST TEST DRIVE THE
PRESSURE SENSOR.* VEHICLE AND PERFORM DOES THE DRB YES REPLACE THE ENGINE
TURN IGNITION ON SEVERAL KEY CYCLES. DISPLAY THIS CODE? CONTROL MODULE.*
AND CLEAR CODES. USING THE DRB, READ
CODES.
NO
TEST COMPLETE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
85
ProCarManuals.com

TEST TC-20ACONTINUED - REPAIRING - BRAKE SWITCH PLAUSIBILITY WITH REDUNDANT
CONTACT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-20A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS BRAKE LAMP SWITCH
PAGE. HARNESS
CONNECTOR.**
USING A VOLTMETER,
PROBE BRAKE SWITCH IS THE VOLTAGE NO REPAIR OPEN FUSED
HARNESS CONNECTOR ABOVE 9.0 VOLTS? BATTERY SUPPLY
CAVITY 6. CIRCUIT.*
FIG.1
YES
CONNECT A JUMPER
WIRE ACROSS THE DID THE DRB CHANGE YES ADJUST OR REPLACE
BRAKE LAMP FROM "RELEASED" TO THE BRAKE LAMP
HARNESS CONNECTOR "PRESSED"? SWITCH.*
CAV 5 AND 6. FIG.1
NO
KEY ON. USING A AT THE BRAKE LAMP REPAIR THE PRIMARY
VOLTMETER, MEASURE SWITCH HARNESS IS THE VOLTAGE YES BRAKE LAMP SWITCH
THE PRIMARY SWITCH CONNECTOR CAVITY 5. ABOVE 1.0 VOLT? SIGNAL CIRCUIT FOR
SIGNAL VOLTAGE... A SHORT TO
FIG.1 VOLTAGE.*
NO
KEY OFF. USING AN OHMMETER, REPAIR THE OPEN
DISCONNECT THE ECM MEASURE RESISTANCE IS THE RESISTANCE NO PRIMARY BRAKE LAMP
HARNESS OF THE PRIMARY BRAKE BELOW 5.0 OHMS? SWITCH SIGNAL
CONNECTORS.** LAMP SWITCH SIGNAL CIRCUIT.*
CIRCUIT. FIG.2
YES
REPLACE THE ENGINE
CONTROL MODULE.* SW
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
89
ProCarManuals.com

TEST TC-20BREPAIRING - BRAKE SWITCH PLAUSIBILITY WITH REDUNDANT CONTACT
Perform TEST TC-20A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST
TC-20B. TURN IGNITION OFF.
DISCONNECT THE KEY ON. USING A
BRAKE LAMP SWITCH VOLTMETER, MEASURE IS THE VOLTAGE NO CONTINUE TEST
HARNESS HARNESS CONNECTOR ABOVE 9.0 VOLTS? TC-20B ON THE
CONNECTOR.** CAVITY 1. NEXT PAGE.
FIG.1
YES
CONNECT A FUSEDREPAIR THE
JUMPER WIRE (5 AMP),YES SECONDARY BRAKE SW
ACROSS BRAKE LAMP CHECK THE FUSE. DID FUSE OPEN? SENSE CIRCUIT FOR
SWITCH HARNESS CONN A SHORT TO
CAVITIES 1 AND 2. VOLTAGE.*
NO
DID THE DRB
DISPLAY CHANGE YES ADJUST OR REPLACE
FROM "PRESSED" TO THE BRAKE LAMP
"RELEASED"? SWITCH.*
NO
KEY OFF. BRAKE LAMP SWITCH REPAIR THE OPEN
USING AN OHMMETER, HARNESS CONNECTOR IS THE RESISTANCE NO SECONDARY BRAKE
MEASURE THE CAVITY 2 AND GROUND. BELOW 5.0 OHMS? LAMP SWITCH GROUND
RESISTANCE CIRCUIT.*
BETWEEN... FIG.1
YES
REPLACE THE ENGINE
CONTROL MODULE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
91
ProCarManuals.com