relay CHRYSLER CARAVAN 2000 User Guide

TEST DTCCHECKING FOR DIAGNOSTIC TROUBLE CODES
NOTE: The battery must be fully charged for any test in this manual.
1. Attempt to start the engine. Crank for up to 10 seconds if necessary.
2. Connect the DRB to the data link connector. Write down the trouble codes that are displayed.
3. If the DRB displays ``No Response'', go toTEST NS-2A.
4. If the DRB screen is blank or has a DRB error message, go toGeneral Information Section
3.5in this manual.
5. Iftrouble code messagesare displayed, refer to the trouble code list below and on the
following page for the appropriate test.
6. If there are no ECM trouble codes displayed, refer to one of the following:
For Immobilizer problems..................................................SK-1A
For Driveability problems.................................................NTC-1A
For No Start problems....................................................NS-1A
For Speed Control problems...............................................SC-1A
NOTE:For all component locations see General Information Section 4.0 in this manual.
DRB DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYEDDIAGNOSTIC
TESTSCAN
TOOL
AC Control Short CircuitTC-1 P1655
A/C Control Open CircuitTC-2 P1655
A/C System Pressure Signal High Exceeded TC-3 P1695
A/C System Pressure Signal Low Exceeded TC-4 P1695
A/C System Pressure Supply High Exceeded TC-5 P1695
A/C System Pressure Supply Low Exceeded TC-6 P1695
Accelerator Pedal Sensor High Exceeded TC-7 P1515
Accelerator Pedal Sensor PlausibilityTC-7 P1515
Accelerator Pedal Sensor Pwg Plaus With Low Idle Switch TC-7 P1515
Accelerator Pedal Sensor Pwg Plaus With Potentiometer TC-7 P1515
Atmospheric Pressure Sensor SRC High Exceeded ** P1105
Atmospheric Pressure Sensor SRC Low Exceeded ** P1105
Battery Voltage SRC High Exceeded TC-14 P1600
Turbocharger Boost Sensor Signal High Exceeded TC-15 P0235
Turbocharger Boost Sensor Signal Low Exceeded TC-16 P0235
Turbocharger Boost Sensor Supply High Exceeded TC-17 P0235
Turbocharger Boost Sensor Supply Low Exceeded TC-18 P0235
Turbocharger Boost Sensor Plausibility TC-19 P0235
Brake Signal Plaus With Redundant Contact TC-20 P1703
Clutch Signal PlausibilityTC-21 P1740
Control Sleeve Sensor Signal High Exceeded TC-22 P1225
Control Sleeve Sensor Start End Pos. Not Attained TC-23 P1225
Control Sleeve Sensor Stop End Pos. Not Attained TC-24 P1225
Cruise Status Indicator Lamp Short Circuit TC-25 P1665
Diagnostic Lamp Open CircuitTC-26 P1650
Diagnostic Lamp Short CircuitTC-27 P1650
Diesel Power Relay Shuts Off Too Early TC-30 P1625
Diesel Power Relay Shuts Off Too Late TC-31 P1625
EEPROM Plausibility Checksum Error For Adj. ** P1680
EEPROM Plausibility Checksum Error in CC212 ** P1680
EEPROM Plausibility Communication with EEPROM ** P1680
EEPROM Plausibility Func. Switch Wrong or Missing ** P1680
EEPROM Plausibility Ver. Number Not Corresponding ** P1680
EGR Open CircuitTC-33 P0400
EGR Short CircuitTC-34 P0400
Engine Speed Sensor Dynamic Plausibility TC-35 P0725
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TEST DTCCHECKING FOR DIAGNOSTIC TROUBLE CODES
DRBIIITDIAGNOSTIC TROUBLE CODE (DTC) DISPLAYEDDIAGNOSTIC
TESTSCAN
TOOL
Engine Speed Sensor Over Speed Recognition TC-36 P0725
Engine Speed Sensor Static Plausibility TC-38 P0725
Fan Control Open Circuit Fan #1TC-39 P1690
Fan Control Open Circuit Fan #2TC-40 P1690
Fan Control Short Circuit Fan #1TC-41 P1690
Fan Control Short Circuit Fan #2TC-42 P1690
Fuel Quantity Actuator Neg. Gov. Deviation Cold TC-43 P1220
Fuel Quantity Actuator Neg. Gov. Deviation Warm TC-44 P1220
Fuel Quantity Actuator Pos. Gov. Deviation Cold TC-45 P1220
Fuel Quantity Actuator Pos. Gov. Deviation Warm TC-46 P1220
Fuel Temperature Sensor SRC High Exceeded TC-47 P0180
Fuel Temperature Sensor SRC Low Exceeded TC-48 P0180
Glow Relay #1 Controller Open Circuit TC-51 P1635
Glow Relay #2 Controller Open Circuit TC-52 P1635
Glow Relay #1 Controller Short Circuit TC-53 P1635
Glow Relay #2 Controller Short Circuit TC-54 P1635
Inductive Aux. Speed Sensor Dynamic Plausibility TC-56 P1725
Inductive Aux. Speed Sensor Overspeed Recognition TC-57 P1725
Inductive Aux. Speed Sensor Plausibility TC-58 P1725
Inductive Aux. Speed Sensor Static Plausibility TC-59 P1725
Intake Air Temperature Sensor Signal High Exceeded TC-62 P0110
Intake Air Temperature Sensor Signal Low Exceeded TC-63 P0110
Microcontroller Gate-array Monitoring** P1615
Microcontroller Gate-array Watchdog** P1615
Microcontroller Prepare Fuel Quantity Stop ** P1615
Microcontroller Recovery Has Occurred ** P1615
Microcontroller Redundant Overrun Monitoring ** P1615
Needle Movement Sensor High Exceeded TC-72 P1201
Needle Movement Sensor Low Exceeded TC-73 P1201
Redundant Emer. Stop Plausibility in After-run TC-74 P1660
Redundant Emer. Stop Powerstate Defective TC-75 P1660
Regulator Lower Regulator Limit** P1610
Regulator Upper Regulator Limit** P1610
Smart Start Relay Short CircuitTC-76 P1675
Solenoid Valve Controller Open Circuit TC-79 P1630
Solenoid Valve Controller Short Circuit TC-80 P1630
Temperature of Engine Coolant SRC High Exceeded TC-81 P0115
Temperature of Engine Coolant SRC Low Exceeded TC-82 P0115
Terminal #15 Plausibility After Start-up TC-84 P1605
Timing Governing Negative Governor Deviation TC-85 P1230
Timing Governing Positive Governor Deviation TC-86 P1230
UþREF (2.5V)** P1620
Vehicle Speed Sensor Pec Frequency Too High TC-91 P0500
Vehicle Speed Sensor Signal High Exceeded TC-91 P0500
Vehicle Speed Sensor PlausibilityTC-91 P0500
Immobilizer Signal LostTC-94 P1685
Invalid SKIM MessageTC-94 P1685
** These trouble codes indicate an internal ECM fault. Using the DRB, clear ECM trouble code(s).
Perform several engine run cycles turning the ignition off for at least 10 seconds between cycles.
Using the DRB, read ECM trouble codes. If the code is present, replace the Engine Control Module.
NOTE: If trouble code TERMINAL 15 PLAUSIBILITY AFTER START-UP is present with other trouble
codes, perform TC-84 diagnosis first.
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TEST TC-1ACONTINUED - REPAIRING - A/C CONTROL SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-1A TURN IGNITION ON.
CONTINUED FROM IS THE A/C CLUTCH NO CONTINUE TEST
THE PREVIOUS WITH THE DRB, RELAY CLICKING? TC-1A ON THE
PAGE. ACTUATE THE A/C NEXT PAGE.
CLUTCH RELAY.
YES
THE CONDITION TO SET USING THE SCHEMATIC
THE TROUBLE CODE IS AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
NOT PRESENT. THE WIRING AND FOUND? NECESSARY.*
CONNECTORS.
FIG.1 FIG.2
NO
WIGGLE THE WIRING NOTE: THE DRB MUST REPAIR AS
HARNESS FROM THE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
RELAY TO THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
ENGINE CONTROL RELAY. CLICKING? CLICKING TO BE
MODULE.INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-1ACONTINUED - REPAIRING - A/C CONTROL SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-1A
CONTINUED FROM TURN IGNITION OFF.
THE PREVIOUS REMOVE THE A/C
PAGE. CLUTCH RELAY.**
USING AN OHMMETER, 85 AND 86 IS THE RESISTANCE
MEASURE RESISTANCE 85 AND 87 BELOW 30.0 OHMS YES REPLACE THE A/C
BETWEEN A/C CLUTCH 85 AND 30 FOR ANY OF THE CLUTCH RELAY.*
RELAY TERMINALS... 85 AND 87A MEASUREMENTS?
FIG.2
NO
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.3 STEP.
MEASURE THE RELAYREPAIR A/C CLUTCH
CONTROL CIRCUIT AT IS THE VOLTAGE YES RELAY CONTROL
RELAY CONNECTOR ABOVE 1.0 VOLT? CIRCUIT FOR SHORT
(IN PDC).TO VOLTAGE.*
FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-2ACONTINUED - REPAIRING - A/C CONTROL OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-2A TURN IGNITION ON.
CONTINUED FROM IS THE A/C CLUTCH NO CONTINUE TEST
THE PREVIOUS WITH THE DRB, RELAY CLICKING? TC-2A ON THE
PAGE. ACTUATE THE A/C NEXT PAGE.
CLUTCH RELAY.
YES
THE CONDITION TO SET USING THE SCHEMATIC
THE TROUBLE CODE IS AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
NOT PRESENT. THE WIRING AND FOUND? NECESSARY.*
CONNECTORS.
FIG.1 FIG.2
NO
WIGGLE THE WIRING NOTE: THE DRB MUST REPAIR AS
HARNESS FROM THE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
RELAY TO THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
ENGINE CONTROL RELAY. CLICKING? CLICKING TO BE
MODULE.INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-2ACONTINUED - REPAIRING - A/C CONTROL OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-2A
CONTINUED FROM KEY OFF.
THE PREVIOUS REMOVE THE A/C
PAGE. CLUTCH RELAY.**
USING A VOLTMETER,
MEASURE THE DIESEL IS THE VOLTAGE NO REPAIR THE OPEN
TURN IGNITION ON. POWER RELAY OUTPUT ABOVE 10.0 VOLTS? DIESEL POWER RELAY
CIRCUIT. OUTPUT CIRCUIT.*
FIG.1
YES
KEY OFF. MEASURE THE
RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE A/C
USE AN OHMMETER IN A/C CLUTCH RELAY BELOW 100.0 OHMS? CLUTCH RELAY.*
THE FOLLOWING TERMINALS 85 AND 86.
STEPS. FIG.2
YES
MEASURE THE REPAIR THE A/C
DISCONNECT THE ECM RESISTANCE BETWEEN IS THE RESISTANCE YES CLUTCH RELAY
HARNESS GND AND THE A/C BELOW 5.0 OHMS? CONTROL CKT FOR A
CONNECTORS.** CLUTCH RELAY CONTROL SHORT TO GROUND.*
CKT (IN PDC). FIG.1
NO
MEASURE THE FROM THE RELAY TO
RESISTANCE OF THE THE ECM. IS THE RESISTANCE NO REPAIR OPEN A/C
A/C CLUTCH RELAY BELOW 5.0 OHMS? CLUTCH RELAY
CONTROL CIRCUIT... CONTROL CKT.*
FIG.3
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-5ACONTINUED - REPAIRING - A/C SYSTEM PRESSURE SUPPLY HIGH EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-5A TURN IGNITION OFF.
CONTINUED FROM DISCONNECT THE A/C
THE PREVIOUS PRESSURE SENSOR
PAGE. HARNESS
CONNECTOR.**
DISCONNECT THE ECM REMOVE THE DIESEL
HARNESS POWER RELAY.**
CONNECTORS.**
WITH A JUMPER WIRE, KEY ON.
CONNECT DIESEL POWER
RELAY CONN. CAVITIES USE A VOLTMETER IN
30 AND 87 (IN PDC). THE FOLLOWING
FIG.1 STEP.
MEASURE THE A/C REPAIR THE A/C
PRESSURE SENSOR IS THE VOLTAGE YES PRESSURE SENSOR
SUPPLY CIRCUIT. ABOVE 1.0 VOLT? SUPPLY CIRCUIT FOR
A SHORT TO
FIG.2 VOLTAGE.*
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-7CREPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE CODES
Perform TEST TC-7A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST DISCONNECT THE ECM
TC-7C. TURN IGNITION OFF. HARNESS
CONNECTORS.**
MEASURE BETWEEN REPAIR THE 5-VOLT
USE AN OHMMETER IN GROUND AND THE IS THE RESISTANCE YES SUPPLY CIRCUIT FOR
THE FOLLOWING 5-VOLT SUPPLY CKT. BELOW 5.0 OHMS? A SHORT TO
STEPS. GROUND.*
FIG.1
NO
EACH GROUND CIRCUIT REPAIR THE 5-VOLT
MEASURE BETWEEN AT ACCEL PEDAL IS THE RESISTANCE YES SUPPLY CIRCUIT FOR
THE 5-VOLT SUPPLY SENSOR HARNESS CONN BELOW 5.0 OHMS? A SHORT TO SENSOR
CIRCUIT AND... CAVITIES 3 AND 8. GROUND.*
FIG.1
NO
WITH A JUMPER WIRE,
REMOVE THE DIESEL CONNECT DIESEL POWER
POWER RELAY.** RELAY CONN. CAVITIES
30 AND 87 (IN PDC).
FIG.2
USING A VOLTMETER, REPAIR THE 5-VOLT
MEASURE THE 5-VOLT IS THE VOLTAGE YES SUPPLY CIRCUIT FOR
TURN IGNITION ON. SUPPLY CKT. ABOVE 1.0 VOLT? A SHORT TO
VOLTAGE.*
FIG.1
NO
USING AN OHMMETER,
MEASURE THE IS THE RESISTANCE NO REPAIR THE OPEN
TURN IGNITION OFF. RESISTANCE OF THE BELOW 5.0 OHMS? 5-VOLT SUPPLY
5-VOLT SUPPLY CKT. CIRCUIT.*
FIG.3
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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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.**
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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
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