check engine CHRYSLER CARAVAN 2000 Workshop Manual

TEST TC-27ACONTINUED - REPAIRING - DIAGNOSTIC LAMP SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-27A
CONTINUED FROM
THE PREVIOUS TURN IGNITION OFF.
PAGE.
DISCONNECT THE
MESSAGE CENTER
HARNESS TURN IGNITION ON.
CONNECTOR.**
USING A VOLTMETER, AT THE MESSAGE REPAIR DIAG/GLOW
MEASURE THE CENTER HARNESS IS THE VOLTAGE YES PLUG LAMP CIRCUIT
DIAG/GLOW LAMP CONNECTOR. ABOVE 1.0 VOLT? FOR A SHORT TO
CONTROL CKT... VOLTAGE.*
FIG. 1
NO
DOES THE DRB
CLEAR FAULT CODES. TURN IGNITION ON. DISPLAY YES REPLACE THE ENGINE
TURN IGNITION OFF READ DRB FAULT "DIAGNOSTIC LAMP CONTROL MODULE.*
FOR 30 SECONDS. CODES. SHORT CIRCUIT"?
NO
CHECK FOR SHORTED
DIAG/GLOW PLUG
LAMP. IF OK,
REPLACE THE
MESSAGE CENTER.*
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TEST TC-30ACONTINUED - REPAIRING - DIESEL POWER RELAY SHUTS OFF TO EARLY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-30A KEY OFF.
CONTINUED FROM SUBSTITUTE THE
THE PREVIOUS DIESEL POWER RELAY
PAGE. WITH A KNOWN GOOD
RELAY.
PERFORM SEVERAL TURN IGNITION ON.
KEY CYCLES PAUSING DOES THIS CODE NO REPLACE THE
FOR AT LEAST 10 USING THE DRB, APPEAR? INITIAL DIESEL
SECONDS BETWEEN READ CODES. POWER RELAY.*
EACH CYCLE.
YES
KEY OFF.
DISCONNECT THE ECM
REMOVE THE DIESEL HARNESS
POWER RELAY.** CONNECTORS.**
FIG.1
USING AN OHMMETER, WIGGLING THE WAS THE RESISTANCE REPAIR THE
MEASURE RESISTANCE WIRING AND ABOVE 5.0 OHMS AT YES INTERMITTENT OPEN
OF THE DIESEL POWER CONNECTORS BETWEEN ANY TIME WHILE IN THE DIESEL
RELAY CONTROL CKT THE ECM AND PDC. WIGGLING? POWER RELAY
WHILE... FIG.1 CONTROL CIRCUIT.*
NO
REINSTALL THE DIESEL
POWER RELAY.
RECONNECT THE ECM
HARNESS CONNECTORS.
PERFORM SEVERAL TURN IGNITION ON.
KEY CYCLES PAUSING DOES THIS CODE YES REPLACE THE ENGINE
FOR AT LEAST 10 USING THE DRB, APPEAR? CONTROL MODULE.*
SECONDS BETWEEN READ CODES.
EACH CYCLE.
NO
TEST COMPLETE.*
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TEST TC-31ACONTINUED - REPAIRING - DIESEL POWER RELAY SHUTS OFF TOO LATE
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-31A KEY OFF.
CONTINUED FROM SUBSTITUTE THE
THE PREVIOUS DIESEL POWER RELAY
PAGE. WITH A KNOWN GOOD
RELAY. FIG.1
PERFORM SEVERAL TURN IGNITION ON.
KEY CYCLES PAUSING DOES THIS CODE NO REPLACE THE
FOR AT LEAST 10 USING THE DRB, APPEAR? INITIAL DIESEL
SECONDS BETWEEN READ CODES. POWER RELAY.*
EACH CYCLE.
YES
KEY OFF.
DISCONNECT THE ECM
REMOVE THE DIESEL HARNESS
POWER RELAY.** CONNECTORS.**
FIG.1
USING AN OHMMETER, WIGGLING THE WAS THE RESISTANCE REPAIR THE
MEASURE RESISTANCE WIRING AND BELOW 5.0 OHMS AT YES INTERMITTENT SHORT
BETWEEN GROUND AND CONNECTORS BETWEEN ANY TIME WHILE TO GROUND IN THE
DIESEL POWER RELAY THE ECM AND PDC. WIGGLING? DIESEL POWER RELAY
CONTROL CKT WHILE... FIG.1 CONTROL CIRCUIT.*
NO
REINSTALL THE DIESEL
POWER RELAY.
RECONNECT THE ECM
HARNESS CONNECTORS.
PERFORM SEVERAL TURN IGNITION ON.
KEY CYCLES PAUSING DOES THIS CODE YES REPLACE THE ENGINE
FOR AT LEAST 10 USING THE DRB, APPEAR? CONTROL MODULE.*
SECONDS BETWEEN READ CODES.
EACH CYCLE.
NO
TEST COMPLETE.*
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TEST TC-33ACONTINUED - REPAIRING - EGR OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-33A TURN IGNITION OFF.
CONTINUED FROM DISCONNECT THE EGR
THE PREVIOUS SOLENOID HARNESS
PAGE. CONNECTOR.**
KEY ON. USING A
VOLTMETER, MEASURE IS THE VOLTAGE YES REPAIR THE OPEN
THE DIESEL POWER BELOW 10.0 VOLTS? DIESEL POWER RELAY
RELAY OUTPUT CKT. OUTPUT CKT.*
FIG.1
NO
TURN IGNITION OFF. USING AN OHMMETER, REPAIR THE SHORT
DISCONNECT THE ECM MEASURE THE EGR IS THE RESISTANCE YES TO GROUND OF THE
HARNESS SOLENOID CONTROL BELOW 5.0 OHMS? EGR SOLENOID
CONNECTORS.** CIRCUIT TO GROUND. CONTROL CKT.*
FIG.1
NO
USING AN OHMMETER,
MEASURE THE EGR IS THE RESISTANCE YES REPAIR THE OPEN
SOLENOID CONTROL ABOVE 5.0 OHMS? EGR SOLENOID
CIRCUIT. CONTROL CKT.*
FIG.2
NO
RECONNECT THE ECM
REPLACE THE EGR AND EGR SOLENOID DOES THE EGR CODE YES REPLACE THE ENGINE
SOLENOID. CONNECTORS. KEY RESET? CONTROL MODULE.*
ON. USING THE DRB,
CHECK FOR CODES.
NO
TEST COMPLETE.*
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TEST TC-35AREPAIRING - ENGINE SPEED SENSOR DYNAMIC PLAUSIBILITY
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST ATTEMPT TO START DOES THE ENGINE NO CONTINUE TEST
TC-35A. AND IDLE THE START AND IDLE? TC-35A ON THE
ENGINE. NEXT PAGE.
YES
USE THE SCHEMATIC AS DOES THE DRB REPAIR THE HARNESS
WITH THE ENGINE A GUIDE AND WIGGLE DISPLAY "ENGINE YES OR CONNECTOR THAT
STILL RUNNING... THE ENGINE SPEED SPEED SENSOR CAUSED THE CODE TO
SENSOR CONNECTOR & DYNAMIC SET.*
HARNESS. FIG.1 PLAUSIBILITY"?
NO
AT THIS TIME, THE USING THE SCHEMATIC
CONDITION REQUIRED AS A GUIDE, INSPECT WERE ANY PROBLEMS REPAIR AS
TO SET THE CODE IS THE WIRING AND FOUND? NECESSARY.*
NOT PRESENT. CONNECTORS. YES
FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-35ACONTINUED - REPAIRING - ENGINE SPEED SENSOR DYNAMIC PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY OFF.
TEST TC-35A DISCONNECT ENGINE
CONTINUED FROM SPEED SENSOR AND
PREVIOUS PAGE. THE ECM HARNESS
CONNECTORS.**
MEASURE RESISTANCE REPAIR THE SHORT
USE AN OHMMETER IN BETWEEN GROUND AND IS THE RESISTANCE YES TO GROUND ON THE
THE FOLLOWING ENGINE SPEED BELOW 5.0 OHMS? ENGINE SPEED
STEPS. SENSOR SIGNAL CKT. SENSOR CKT.*
FIG.1
NO
MEASURE RESISTANCE REPAIR THE ENGINE
BETWEEN THE ENGINE IS THE RESISTANCE YES SPEED SENSOR
SPEED SENSOR SIGNAL BELOW 5.0 OHMS? CIRCUIT FOR A
CKT AND SENSOR SHORT TO SENSOR
GROUND. FIG.1 GROUND.*
NO
MEASURE THE
RESISTANCE OF THE IS THE RESISTANCE YES REPAIR THE OPEN
ENGINE SPEED ABOVE 5.0 OHMS? ENGINE SPEED
SENSOR CIRCUIT. SENSOR CKT.*
FIG.2
NO
WITH A JUMPER KEY ON. USING A REPAIR THE SHORT
WIRE, CONNECT ECM VOLTMETER, MEASURE IS THE VOLTAGE YES TO VOLTAGE ON THE
HARNESS CONNECTOR THE ENGINE SPEED ABOVE 0.5 VOLTS? ENGINE SPEED
CAVITY 33 TO SENSOR CIRCUIT. SENSOR CKT.*
GROUND. FIG.1
NO
KEY OFF. REMOVE USING A VOLTMETER TO WITH ENGINE RUNNING,
JUMPER WIRE. MEASURE FREQUENCY, IS FREQUENCY BETWEEN YES REPLACE THE ENGINE
RECONNECT ECM AND BACKPROBE ECM 44 AND 64HZ AT 850 CONTROL MODULE.*
ENGINE SPEED SENSOR HARNESS CONNECTOR RPM AND 150 AND
HARNESS CONNECTORS. CAVITY 67. FIG.2 190HZ AT 2500 RPM?
NO
REPLACE THE ENGINE
SPEED SENSOR.*
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TEST TC-36AREPAIRING - ENGINE SPEED SENSOR OVERSPEED RECOGNITION
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: THIS CODE
START TEST INDICATES THE ENGINE
TC-36A. SPEED SENSOR HAS
SEEN AN ENGINE SPEED
OF ABOVE 5400 RPM.
USING THE DRB,
CHECK FOR OTHER ARE ANY OTHER YES REPAIR OTHER CODES
ENGINE SPEED CODES SET? FIRST.*
SENSOR CODES.
NO
CHECK ENGINE SPEED
WITH THE DRB, SENSOR WIRING FOR WERE ANY PROBLEMS YES REPAIR AS
ERASE THE CODE. INCORRECT ROUTING FOUND? NECESSARY.*
AND CONNECTIONS
WHICH MAY CAUSE EMI.
NO
DOES THE DRB
TEST DRIVE WITH THE DRB, READ DISPLAY "ENGINE NO
VEHICLE. TROUBLE CODES. SPEED SENSOR TEST COMPLETED.*
OVERSPEED
RECOGNITION"?
YES
TEST DRIVE THE DOES THE DRB
REPLACE THE ENGINE VEHICLE. WITH THE DISPLAY "ENGINE NO
SPEED SENSOR. DRB, READ TROUBLE SPEED SENSOR TEST COMPLETED.*
CODES. OVERSPEED
RECOGNITION"?
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-38AREPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST ATTEMPT TO START DOES THE ENGINE NO CONTINUE TEST
TC-38A. AND IDLE THE START AND IDLE? TC-38A ON THE
ENGINE. NEXT PAGE.
YES
USE THE SCHEMATIC AS DOES THE DRB REPAIR THE HARNESS
WITH THE ENGINE A GUIDE AND WIGGLE DISPLAY "ENGINE YES OR CONNECTOR THAT
STILL RUNNING... THE ENGINE SPEED SPEED SENSOR CAUSED THE CODE TO
SENSOR CONNECTOR & STATIC SET.*
HARNESS. FIG.1 PLAUSIBILITY"?
NO
AT THIS TIME, THE USING THE
CONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
TO SET THE CODE IS GUIDE, INSPECT THE FOUND? NECESSARY.*
NOT PRESENT. WIRING AND
FIG.2 CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-38ACONTINUED - REPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY OFF.
TEST TC-38A DISCONNECT ENGINE
CONTINUED FROM SPEED SENSOR AND
PREVIOUS PAGE. THE ECM HARNESS
CONNECTORS.**
MEASURE RESISTANCE REPAIR THE SHORT
USE AN OHMMETER IN BETWEEN GROUND AND IS THE RESISTANCE YES TO GROUND ON THE
THE FOLLOWING THE ENGINE SPEED BELOW 5.0 OHMS? ENGINE SPEED
STEPS. SENSOR SIGNAL CKT. SENSOR CKT.*
FIG. 1
NO
MEASURE RESISTANCE REPAIR THE ENGINE
BETWEEN ENGINE SPEED IS THE RESISTANCE YES SPEED SENSOR
SENSOR SIGNAL CKT BELOW 5.0 OHMS? CIRCUIT FOR A
AND SENSOR GROUND. SHORT TO SENSOR
FIG. 1 GROUND.*
NO
MEASURE THE
RESISTANCE OF THE IS THE RESISTANCE YES REPAIR THE OPEN
ENGINE SPEED ABOVE 5.0 OHMS? ENGINE SPEED
SENSOR CIRCUIT. SENSOR CKT.*
FIG.2
NO
WITH A JUMPER KEY ON. USING A REPAIR THE SHORT
WIRE, CONNECT ECM VOLTMETER, MEASURE IS THE VOLTAGE YES TO VOLTAGE ON THE
HARNESS CONNECTOR THE ENGINE SPEED ABOVE 0.5 VOLTS? ENGINE SPEED
CAVITY 33 TO SENSOR CIRCUIT. SENSOR CKT.*
GROUND. FIG.1
NO
KEY OFF. RECONNECT USING A VOLTMETER TO WITH ENGINE RUNNING,
THE ECM AND ENGINE MEASURE FREQUENCY, IS FREQUENCY BETWEEN YES REPLACE THE ENGINE
SPEED SENSOR BACKPROBE ECM 44 AND 64HZ AT 850 CONTROL MODULE.*
HARNESS HARNESS CONNECTOR RPM AND 150 AND
CONNECTORS. CAVITY 67. FIG.2 190HZ AT 2500 RPM?
NO
REPLACE THE ENGINE
SPEED SENSOR.*
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TEST TC-39AREPAIRING - FAN CONTROL OPEN CIRCUIT FAN 1
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON. IS THE RADIATOR
START TEST WITH THE DRB, FAN #2 RELAY NO CONTINUE TEST
TC-39A. ACTUATE THE LOW CLICKING ON AND TC-39A ON THE
SPEED RADIATOR OFF? NEXT PAGE.
FAN.
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 REPAIR AS NECESSARY
HARNESS FROM THE NOTE: THE DRB MUST DID THE WIGGLING YES WHERE WIGGLING
RELAY TO THE STILL BE ACTUATING INTERRUPT FAN CAUSED FAN RELAY
ENGINE CONTROL THE FAN RELAY. RELAY CLICKING? CLICKING TO BE
MODULE.INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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