key CHRYSLER CARAVAN 2000 Workshop Manual

TEST TC-51ACONTINUED - REPAIRING - GLOW RELAY #1 CONTROLLER OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-51A
CONTINUED FROM TURN IGNITION OFF.
THE PREVIOUS REMOVE THE GLOW
PAGE. PLUG #1 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
TURN IGNITION OFF. MEASURE RESISTANCE
USE AN OHMMETER IN BETWEEN CAVITY 85 IS THE RESISTANCE NO REPLACE THE GLOW
THE FOLLOWING AND 86 OF THE GLOW BELOW 100.0 OHMS? PLUG #1 RELAY.*
STEPS. PLUG #1 RELAY.
FIG.2
YES
KEY OFF. MEASURE RESISTANCE REPAIR THE GLOW
DISCONNECT THE ECM BETWEEN GROUND AND IS THE RESISTANCE YES PLUG #1 RELAY
HARNESS THE GLOW PLUG #1 BELOW 5.0 OHMS? CONTROL CKT FOR A
CONNECTORS.** RELAY CONTROL CKT. SHORT TO GROUND.*
FIG.1
NO
MEASURE THE FROM THE RELAY TO
RESISTANCE OF THE THE ECM. IS THE RESISTANCE NO REPAIR OPEN GLOW
GLOW PLUG #1 RELAY BELOW 5.0 OHMS? PLUG #1 RELAY
CONTROL CIRCUIT... CONTROL CKT.*
FIG.3
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-52ACONTINUED - REPAIRING - GLOW RELAY #2 CONTROLLER OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-52A
CONTINUED FROM TURN IGNITION OFF.
THE PREVIOUS REMOVE THE GLOW
PAGE. PLUG #2 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
TURN IGNITION OFF. MEASURE RESISTANCE
USE AN OHMMETER IN BETWEEN CAVITY 85 IS THE RESISTANCE NO REPLACE THE GLOW
THE FOLLOWING AND 86 OF THE GLOW BELOW 100.0 OHMS? PLUG #2 RELAY.*
STEPS. PLUG #2 RELAY.
FIG.2
YES
KEY OFF. MEASURE RESISTANCE REPAIR THE GLOW
DISCONNECT THE ECM BETWEEN GROUND AND IS THE RESISTANCE YES PLUG #2 RELAY
HARNESS THE GLOW PLUG #2 BELOW 5.0 OHMS? CONTROL CKT FOR A
CONNECTORS.** RELAY CONTROL CKT. SHORT TO GROUND.*
FIG.1
NO
MEASURE THE FROM THE RELAY TO
RESISTANCE OF THE THE ECM. IS THE RESISTANCE NO REPAIR OPEN GLOW
GLOW PLUG #2 RELAY BELOW 5.0 OHMS? PLUG #2 RELAY
CONTROL CIRCUIT... CONTROL CKT.*
FIG.3
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-56ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR DYNAMIC
PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-56A DISCONNECT THE
CONTINUED FROM NEEDLE MOVEMENT
PREVIOUS PAGE. SENSOR HARNESS
CONNECTOR.**
INSPECT THE NEEDLE THE SENSOR HARNESS IS THERE ANY
MOVEMENT SENSOR AND ENGINE HARNESS. DAMAGE OR YES REPAIR AS
CONNECTOR CORROSION AT NECESSARY.*
TERMINALS AT EITHER HARNESS
BOTH.... FIG.1 AND 2. CONNECTOR?
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REPAIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD INDUCE CARRYING WIRES OR MIS-ROUTED?
INTERFERENCE. THE ALTERNATOR.
NO
DISCONNECT THE ECM THE NEEDLE REPAIR THE OPEN IN
HARNESS MOVEMENT SENSOR IS THE RESISTANCE YES THE NEEDLE
CONNECTORS.** USING SIGNAL CIRCUIT. ABOVE 5.0 OHMS? MOVEMENT SENSOR
AN OHMMETER, MEASURESIGNAL CIRCUIT.*
THE RESISTANCE OF... FIG.3
NO
KEY OFF. REPLACE THE START AND OPERATE
NEEDLE MOVEMENT THE ENGINE FROM DOES THIS CODE YES REPLACE THE ENGINE
SENSOR. RECONNECT IDLE TO 3500 RPM RESET? CONTROL MODULE.*
ALL CONNECTORS. KEY WHILE MONITORING
ON. ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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TEST TC-57ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR OVERSPEED
RECOGNITION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-57A DISCONNECT THE
CONTINUED FROM NEEDLE MOVEMENT
PREVIOUS PAGE. SENSOR HARNESS
CONNECTOR.**
INSPECT THE NEEDLE THE SENSOR HARNESS IS THERE ANY
MOVEMENT SENSOR AND ENGINE DAMAGE OR YES REPAIR AS
CONNECTOR HARNESS. CORROSION AT NECESSARY.*
TERMINALS AT EITHER HARNESS
BOTH.... FIG. 1 AND 2 CONNECTOR?
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REPAIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD INDUCE CARRYING WIRES OR MIS-ROUTED?
INTERFERENCE. THE ALTERNATOR.
NO
DISCONNECT THE ECM THE NEEDLE REPAIR THE OPEN IN
HARNESS MOVEMENT SENSOR IS THE RESISTANCE YES THE NEEDLE
CONNECTORS.** USING SIGNAL CIRCUIT. ABOVE 5.0 OHMS? MOVEMENT SENSOR
AN OHMMETER MEASURESIGNAL CIRCUIT.*
THE RESISTANCE OF... FIG.3
NO
REPLACE THE NEEDLE START AND OPERATE
MOVEMENT SENSOR. THE ENGINE FROM DOES THIS CODE YES REPLACE THE ENGINE
RECONNECT ALL IDLE TO 3500 RPM RESET? CONTROL MODULE.*
CONNECTORS. KEY WHILE MONITORING
ON. ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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TEST TC-58ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-58A DISCONNECT THE
CONTINUED FROM NEEDLE MOVEMENT
PREVIOUS PAGE. SENSOR HARNESS
CONNECTOR.**
INSPECT THE NEEDLE THE SENSOR HARNESS IS THERE ANY
MOVEMENT SENSOR AND ENGINE DAMAGE OR YES REPAIR AS
CONNECTOR HARNESS. CORROSION AT NECESSARY.*
TERMINALS AT EITHER HARNESS
BOTH.... FIG. 1 AND 2 CONNECTOR?
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REPAIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD INDUCE CARRYING WIRES OR MIS-ROUTED?
INTERFERENCE. THE ALTERNATOR.
NO
DISCONNECT THE ECM THE NEEDLE REPAIR THE OPEN IN
HARNESS MOVEMENT SENSOR IS THE RESISTANCE YES THE NEEDLE
CONNECTORS.** USING SIGNAL CIRCUIT. ABOVE 5.0 OHMS? MOVEMENT SENSOR
AN OHMMETER, MEASURESIGNAL CIRCUIT.*
THE RESISTANCE OF... FIG.3
NO
REPLACE THE NEEDLE START AND OPERATE
MOVEMENT SENSOR. THE ENGINE FROM DOES THIS CODE YES REPLACE THE ENGINE
RECONNECT ALL IDLE TO 3500 RPM RESET? CONTROL MODULE.*
CONNECTORS. KEY ON WHILE MONITORING
ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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TEST TC-59ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR STATIC
PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-59A TURN IGNITION OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS NEEDLE MOVEMENT
PAGE. SENSOR HARNESS
CONNECTOR.*
INSPECT THE NEDLE THE SENSOR HARNESS
MOVEMENT SENSOR AND THE ENGINE IS THERE DAMAGE OR YES REPAIR AS
CONNECTOR AT HARNESS. CORROSION AT NECESSARY.*
BOTH... EITHER HARNESS?
FIG.1 AND 2.
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REAPIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD CAUSE CARRYING WIRES OR MIS-ROUTED?
INTERFERNCE. THE ALTERNATOR.
NO
USING AN OHMMETER, REPAIR THE OPEN IN
DISCONNECT THE ECM MEASURE THE NEEDLE IS THE RESISTANCE YES THE NEEDLE
HARNESS MOVEMENT SENSOR ABOVE 5.0 OHMS? MOVEMENT SENSOR
CONNECTORS.** SIGNAL CIRCUIT. SIGNAL CIRCUIT.*
FIG.3
NO
REPLACE THE NEEDLE START AND OPERATE
MOVEMENT SENSOR. THE ENGINE FROM DOES THE CODE YES REPLACE THE ENGINE
RECONNECT ALL IDLE TO 3500 RPM RESET? CONTROL MODULE.*
CONNECTORS. KEY WHILE MONITORING
ON. ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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TEST TC-62ACONTINUED - REPAIRING - INTAKE AIR TEMPERATURE SENSOR SIGNAL HIGH
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-62A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS BOOST PRESSURE
PAGE. SENSOR HARNESS
CONNECTOR.**
WITH A JUMPER WIRE, TURN IGNITION ON.
DISCONNECT THE ECM REMOVE THE DIESEL CONNECT DIESEL POWER
HARNESS POWER RELAY.** RELAY CONN. CAVITIES USE A VOLTMETER IN
CONNECTORS.** 30 AND 87 (IN PDC). THE FOLLOWING
FIG.1 STEP.
MEASURE THE IAT REPAIR THE INTAKE
SENSOR SIGNAL IS THE VOLTAGE YES AIR TEMPERATURE
CIRCUIT. ABOVE 1.0 VOLT? SENSOR SIGNAL
CIRCUIT FOR A
FIG.2 SHORT TO VOLTAGE.*
NO
KEY OFF. USING AN OHMMETER, REPAIR THE OPEN
MEASURE THE IAT IS THE RESISTANCE NO INTAKE AIR
REMOVE THE JUMPER SENSOR SIGNAL BELOW 5.0 OHMS? TEMPERATURE SENSOR
WIRE. CIRCUIT. SIGNAL CIRCUIT.*
FIG.3
YES
CONNECT A JUMPER DOES THE DRB
BETWEEN THE INTAKE WITH THE DRB, DISPLAY "INTAKE YES REPLACE THE BOOST
AIR TEMP SENSOR ERASE AND THEN AIR TEMPERATURE PRESSURE SENSOR.*
SIGNAL AND SENSOR READ CODES. SENSOR LOW
GROUND CKT. FIG.1 EXCEEDED"?
NO
MOVE THE JUMPER DOES THE DRB
WIRE FROM THE WITH THE DRB, READ DISPLAY "INTAKE YES REPAIR THE OPEN
SENSOR GROUND TO CODES. AIR TEMPERATURE SENSOR GROUND
AN ENGINE GROUND. SENSOR LOW CIRCUIT.*
EXCEEDED"?
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-63ACONTINUED - REPAIRING - INTAKE AIR TEMPERATURE SENSOR SIGNAL LOW
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY OFF. DISCONNECT
THE BOOST PRESSURE
SENSOR HARNESS
CONNECTOR.**
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TEST TC-72ACONTINUED - REPAIRING - NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-72A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS NEEDLE MOVEMENT
PAGE. SENSOR HARNESS
CONNECTOR.**
CONNECT A JUMPER DOES THE DRB
BETWEEN THE NEEDLE WITH THE DRB, READ DISPLAY "NEEDLE YES REPLACE THE NEEDLE
SENSOR SIGNAL AND CODES. MOVEMENT SENSOR MOVEMENT SENSOR.*
SENSOR GROUND CKT. SRC LOW EXCEEDED"?
FIG.1
NO
MOVE THE JUMPER DOES THE DRB
WIRE FROM THE WITH THE DRB, READ DISPLAY "NEEDLE YES REPAIR THE OPEN
SENSOR GROUND TO CODES. MOVEMENT SENSOR SENSOR GROUND
AN ENGINE GROUND. SRC LOW EXCEEDED"? CIRCUIT.*
NO
KEY OFF. WITH A JUMPER WIRE,
DISCONNECT THE ECM REMOVE THE DIESEL CONNECT DIESEL POWER
HARNESS POWER RELAY. RELAY CONN. CAVITIES
CONNECTORS.** 30 AND 87 (IN PDC).
FIG.2
KEY ON. MEASURE REPAIR THE SHORT
USE A VOLTMETER IN THE NEEDLE IS THE VOLTAGE YES TO VOLTAGE ON THE
THE FOLLOWING MOVEMENT SENSOR ABOVE 0.5 VOLT? NEEDLE MOVEMENT
STEP. SIGNAL CIRCUIT. SENSOR SIGNAL
FIG.1 CIRCUIT.*
NO
KEY OFF. MEASURE THE NEEDLE
MOVEMENT SENSOR IS THE RESISTANCE YES REPLACE THE ENGINE
USE AN OHMMETER IN SIGNAL CIRCUIT. BELOW 5.0 OHMS? CONTROL MODULE.*
THE FOLLOWING
STEP. FIG.3
NO
REPAIR THE OPEN
NEEDLE MOVEMENT
SENSOR SIGNAL
CIRCUIT.*
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TEST TC-73ACONTINUED - REPAIRING - NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-73A DOES THE DRB
CONTINUED FROM DISCONNECT THE DISPLAY "NEEDLE YES REPLACE THE NEEDLE
THE PREVIOUS NEEDLE MOVEMENT MOVEMENT SENSOR MOVEMENT SENSOR.*
PAGE. SENSOR.** SRC HIGH
EXCEEDED"?
NO
KEY OFF. USING AN OHMMETER, REPAIR THE NEEDLE
DISCONNECT THE ECM MEASURE THE NEEDLE IS THE RESISTANCE YES MOVEMENT SENSOR
HARNESS MOVEMENT SENSOR BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
CONNECTORS.** SIGNAL CIRCUIT TO A SHORT TO
GROUND. FIG.1 GROUND.*
NO
WITH AN OHMMETER NEEDLE MOVEMENT REPAIR THE NEEDLE
MEASURE THE SENSOR SIGNAL IS THE RESISTANCE YES MOVEMENT SENSOR
RESISTANCE BETWEEN CIRCUIT AND SENSOR BELOW 5.0 OHMS? SIGNAL CIRCUIT
THE... GROUND CIRCUIT. SHORTED TO THE
FIG.1 SENSOR GND CIRCUIT.*
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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