ignition CHRYSLER CARAVAN 2000 Workshop Manual

TEST TC-43AREPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR DEVIATION COLD
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST USING THE DRB,
TC-43A. ERASE CODES.
TURN IGNITION OFF. DOES THE DRB
WAIT 10 SECONDS. WITH THE DRB, READ DISPLAY "FUEL YES CONTINUE TEST
ATTEMPT TO START CODES. QUANTITY ACTUATOR TC-43A ON THE
AND IDLE THE NEG. DEVIATION NEXT PAGE.
ENGINE. COLD"?
NO
USING THE SCHEMATIC, DOES THE DRB REPAIR THE HARNESS
WIGGLE THE FUEL DISPLAY "FUEL YES OR CONNECTOR THAT
INJECTION PUMP QUANTITY ACTUATOR CAUSED THE TROUBLE
CONNECTOR & HARNESS. NEG. DEVIATION CODE TO SET.*
FIG.1 COLD"?
NO
AT THIS TIME, THE USING A SCHEMATIC
CONDITION REQUIRED AS A GUIDE, WERE ANY PROBLEMS YES REPAIR AS
TO SET THE CODE IS INSPECT THE WIRING FOUND? NECESSARY.*
NOT PRESENT. AND CONNECTORS.
FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-43ACONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR
DEVIATION COLD
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-43A DISCONNECT THE
CONTINUED FROM FUEL INJECTION
PREVIOUS PAGE. PUMP CONNECTOR.**
USING AN OHMMETER CONNECTOR TO
MEASURE CAVITY 8 GROUND ON THE FUEL IS THE RESISTANCE YES REPLACE THE FUEL
OF THE FUEL PUMP INJECTION PUMP, BELOW 5.0 OHMS? INJECTION PUMP
ASSEMBLY... HARNESS SIDE. ASSEMBLY.*
FIG.1
NO
USING AN OHMMETER IS THE RESISTANCE REPAIR THE SHORT
DISCONNECT THE ECM MEASURE THE BELOW 10.0 FOR ANY YES TO GROUND ON THE
HARNESS RESISTANCE TO GROUND OF THE MEASUREMENTS? FUEL QUANTITY
CONNECTORS.** AT ECM CAVITIES 59, ACTUATOR CONTROL
66 AND 80. FIG.2 CIRCUIT.*
NO
NOTE: BEFORE
REPLACING THE ECM, DID FUEL INJECTION YES REPLACE THE ENGINE
PERFORM TEST NTC-3A PUMP PASS TEST CONTROL MODULE.*
TO CHECK INTERNAL NTC-3A?
FUEL PUMP CIRCUITRY.
NO
REPLACE THE FUEL
INJECTION PUMP
ASSEMBLY.*
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TEST TC-44ACONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR
DEVIATION WARM
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-44A DISCONNECT THE
CONTINUED FROM FUEL INJECTION
PREVIOUS PAGE. PUMP CONNECTOR.**
USING AN OHMMETER THE CASE OF THE FUEL
MEASURE CAVITY 8 INJECTION PUMP. IS THE RESISTANCE YES REPLACE THE FUEL
OF THE FUEL PUMP BELOW 5.0 OHMS? INJECTION PUMP
ASSEMBLY CONNECTORASSEMBLY.*
TO... FIG.1
NO
USING AN OHMMETER IS THE RESISTANCE REPAIR THE SHORT
DISCONNECT THE ECM MEASURE THE BELOW 10.0 OHMS YES TO GROUND ON THE
HARNESS RESISTANCE TO GROUND FOR ANY OF THE FUEL QUANTITY
CONNECTORS.** AT ECM CAVITIES 59, MEASUREMENTS? ACTUATOR CONTROL
66 AND 80. FIG.2 CIRCUIT.*
NO
NOTE: BEFORE
REPLACING THE ECM, DID FUEL INJECTION YES REPLACE THE ENGINE
PERFORM TEST NTC-3A PUMP PASS TEST CONTROL MODULE.*
TO CHECK INTERNAL NTC-3A?
FUEL PUMP CIRCUITRY.
NO
REPLACE THE FUEL
INJECTION PUMP
ASSEMBLY.*
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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-53ACONTINUED - REPAIRING - GLOW RELAY #1 CONTROLLER SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-53A
CONTINUED FROM TURN IGNITION OFF.
THE PREVIOUS REMOVE THE GLOW
PAGE. PLUG #1 RELAY.**
USING AN OHMMETER, 85 AND 86 IS THE RESISTANCE
MEASURE RESISTANCE 85 AND 87 BELOW 30.0 OHMS YES REPLACE THE GLOW
BETWEEN GLOW PLUG 85 AND 30 FOR ANY OF THE PLUG #1 RELAY.*
#1 RELAY 85 AND 87A MEASUREMENTS?
TERMINALS... FIG.1
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.2 STEP.
MEASURE THE GLOW REPAIR GLOW PLUG
PLUG #1 RELAY IS THE VOLTAGE YES #1 RELAY CONTROL
CONTROL CIRCUIT. ABOVE 1.0 VOLT? CIRCUIT FOR SHORT
TO VOLTAGE.*
FIG.3
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-54ACONTINUED - REPAIRING - GLOW RELAY #2 CONTROLLER SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-54A
CONTINUED FROM TURN IGNITION OFF.
THE PREVIOUS REMOVE THE GLOW
PAGE. PLUG #2 RELAY.**
USING AN OHMMETER, 85 AND 86 IS THE RESISTANCE
MEASURE RESISTANCE 85 AND 87 BELOW 30.0 OHMS YES REPLACE THE GLOW
BETWEEN GLOW PLUG 85 AND 30 FOR ANY OF THE PLUG #2 RELAY.*
#2 RELAY 85 AND 87A MEASUREMENTS?
TERMINALS... FIG.1
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.2 STEP.
MEASURE THE GLOW REPAIR GLOW PLUG
PLUG #2 RELAY IS THE VOLTAGE YES #2 RELAY CONTROL
CONTROL CIRCUIT. ABOVE 1.0 VOLT? CIRCUIT FOR SHORT
TO VOLTAGE.*
FIG.3
NO
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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