key CHRYSLER CARAVAN 2000 Workshop Manual

TEST TC-74ACONTINUED - REPAIRING - EMERGENCY STOP PLAUSIBILITY IN AFTER-RUN
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-74A KEY OFF.
CONTINUED FROM DISCONNECT THE REMOVE THE DIESEL
THE PREVIOUS FUEL PUMP AND ECM POWER RELAY.**
PAGE. HARNESS
CONNECTORS.**
WITH A JUMPER WIRE, KEY ON. USING A REPAIR THE FUEL
CONNECT DIESEL POWER VOLTMETER, MEASURE IS THE VOLTAGE YES SHUTDOWN SOLENOID
RELAY CONN. CAVITIES THE FUEL SHUTDOWN ABOVE 1.0 VOLT? CONTROL CIRCUIT
30 AND 87 (IN PDC). SOL CONTROL CKT. FOR A SHORT TO
FIG.1 FIG.2 VOLTAGE.*
NO
RECONNECT THE
ENGINE CONTROL KEY ON. USING DRB
MODULE HARNESS ACTUATE THE "FUEL
CONNECTORS. SHUT-OFF SOL."
WITH THE DRB FUEL PUMP HARNESS DOES VOLTMETER
ACTUATING THE CONNECTOR CAVITY 6. CHANGE FROM YES REPLACE FUEL PUMP
SOLENOID, USE A BATTERY VOLTAGE TO ASSEMBLY.*
VOLTMETER TO BELOW 1.0 VOLT?
PROBE... FIG.2
NO
NOTE: BEFORE
REPLACING ECM, DID THE FUEL YES REPLACE THE ENGINE
PERFORM TEST NTC-3A INJECTION PUMP CONTROL MODULE.*
TO CHECK INTERNAL PASS TEST NTC-3A?
FUEL PUMP CIRCUITRY.
NO
REPLACE THE FUEL
INJECTION PUMP
ASSEMBLY.*
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TEST TC-75AREPAIRING - REDUNDANT EMERGENCY STOP POWERSTAGE DEFECTIVE
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST WITH THE DRB,
TC-75A. ERASE CODES.
CYCLE THE IGNITION DOES THE DRB
ON AND OFF SEVERAL WITH THE IGNITION DISPLAY "REDUNDANT YES CONTINUE TEST
TIMES, PAUSING FOR ON ENGINE OFF, EMERG STOP TC-75A ON THE
TEN SECONDS AT KEY READ CODES. POWERSTAGE NEXT PAGE.
ON AND OFF. DEFECTIVE"?
NO
AT THIS TIME THE REVIEW THE CIRCUIT
CONDITION FOR DESCRIPTION FOR A WERE ANY PROBLEMS YES REPAIR AS
SETTING THE CODE PROPER UNDERSTANDING FOUND? NECESSARY.*
IS NOT PRESENT. OF THIS CODE. CHECK
FIG.1 FOR PROBLEMS.
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-75ACONTINUED - REPAIRING - REDUNDANT EMERGENCY STOP POWERSTAGE
DEFECTIVE
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-75A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS FUEL PUMP AND ECM
PAGE. HARNESS
CONNECTORS.**
MEASURE THE
USE AN OHMMETER IN RESISTANCE OF THE IS THE RESISTANCE NO REPAIR OPEN FUEL
THE FOLLOWING FUEL SHUTDOWN BELOW 5.0 OHMS? SHUTDOWN SOLENOID
STEPS. SOLENOID CONTROL CONTROL CIRCUIT.*
CIRCUIT. FIG.1
YES
MEASURE THEREPAIR THE FUEL
RESISTANCE OF THE IS THE RESISTANCE YES SHUTDOWN SOLENOID
FUEL SHUTDOWN SOL. BELOW 5.0 OHMS? CIRCUIT FOR A
CONTROL CIRCUIT TO SHORT TO GROUND.*
GROUND. FIG.2
NO
RECONNECT THE
ENGINE CONTROL KEY ON. USING DRB
MODULE HARNESS ACTUATE THE "FUEL
CONNECTORS. SHUT-OFF SOL."
WITH THE DRB FUEL PUMP HARNESS DOES VOLTMETER
ACTUATING THE CONNECTOR CAVITY 6. CHANGE FROM YES REPLACE FUEL PUMP
SOLENOID, USE A BATTERY VOLTAGE TO ASSEMBLY.*
VOLTMETER TO BELOW 1.0 VOLT?
PROBE... FIG.2
NO
NOTE: BEFORE
REPLACING 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-76AREPAIRING - SMART START RELAY SHORT CIRCUIT
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
REPLACE THE
START TEST STARTER RELAY WITH
TC-76A. A KNOWN GOOD
RELAY.
FIG.1
FULLY DEPRESS THE
CLUTCH PEDAL AND DOES THE ENGINE YES REPLACE THE
ATTEMPT TO CRANK CRANK? INITIAL STARTER
THE ENGINE RELAY.
NO
KEY OFF.
REMOVE THE STARTER REMOVE THE DIESEL
DISCONNECT THE ECM RELAY.** POWER RELAY.**
HARNESS
CONNECTORS.**
WITH A JUMPER WIRE, KEY ON. USING A REPAIR THE STARTER
CONNECT DIESEL POWER TEST LIGHT, PROBE IS THE TEST LIGHT YES RELAY CONTROL
RELAY CONN. CAVITIES THE STARTER RELAY ON? CIRCUIT FOR A
30 AND 87 (IN PDC). CONTROL CIRCUIT. SHORT TO VOLTAGE.*
FIG.1 FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-79AREPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON, READ CODES.
START TEST TURN IGNITION OFF. DOES THE DRB DISPLAY YES CONTINUE TEST
TC-79A. WITH THE DRB, "SOLENOID VALVE TC-79A ON THE
ERASE CODES. CONTROLLER OPEN NEXT PAGE.
CIRCUIT"?
NO
USE THE SCHEMATIC AS DOES THE DRB REPAIR THE HARNESS
A GUIDE AND WIGGLE MONITOR THE DRB DISPLAY "SOLENOID YES OR CONNECTOR THAT
THE SOLENOID VALVE DISPLAY. VALVE CONTROLLER CAUSED THE CODE TO
CONNECTOR & HARNESS. OPEN CIRCUIT"? SET.*
FIG.1
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-79ACONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-79A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS FUEL PUMP ASSEMBLY
PAGE. HARNESS
CONNECTOR.**
KEY ON. MEASURE FUEL
USE A VOLTMETER IN PUMP HARNESS IS THE VOLTAGE YES REPAIR THE OPEN
THE FOLLOWING CONNECTOR CAVITY 10. BELOW 10.5 VOLTS? DIESEL POWER RELAY
STEP.OUTPUT CIRCUIT*
FIG.1
NO
TURN IGNITION OFF. USING AN OHMMETER, REPAIR THE FUEL
DISCONNECT THE ECM MEASURE THE FUEL IS THE RESISTANCE YES TIMING SOLENOID
HARNESS TIMING SOLENOID BELOW 5.0 OHMS? CONTROL CIRCUIT
CONNECTORS.** CONTROL CIRCUIT TO FOR A SHORT TO
GROUND. FIG.1 GROUND.*
NO
MEASURE THE FUEL REPAIR THE OPEN
USE AN OHMMETER IN TIMING SOLENOID IS THE RESISTANCE YES FUEL TIMING
THE FOLLOWING CONTROL CKT BETWEEN ABOVE 5.0 OHMS? SOLENOID CONTROL
STEPS. THE ECM AND THE FUEL CIRCUIT.*
PUMP ASSEMBLY. FIG.2
NO
MEASURE THE PUMP CONNECTOR (PUMP
RESISTANCE OF THE SIDE) BETWEEN IS THE RESISTANCE NO REPLACE THE FUEL
FUEL TIMING CAVITIES 5 AND 10. BETWEEN 12.0 AND INJECTION PUMP
SOLENOID AT THE 20.0 OHMS? ASSEMBLY.*
INJECTION... FIG.3
YES
NOTE: BEFORE
REPLACING THE ECM, DID THE FUEL YES REPLACE THE ENGINE
PERFORM TEST NTC-3A INJECTION PUMP CONTROL MODULE.*
TO CHECK INTERNAL PASS TEST NTC-3A?
FUEL PUMP CIRCUITRY.
NO
REPLACE THE FUEL
INJECTION PUMP
ASSEMBLY.*
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TEST TC-80AREPAIRING - SOLENOID VALVE CONTROLLER SHORT CIRCUIT
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON, READ CODES.
START TEST WITH THE DRB, DOES THE DRB DISPLAY YES CONTINUE TEST
TC-80A. ERASE CODES. TURN "SOLENOID VALVE TC-80A ON THE
IGNITION OFF. CONTROLLER SHORT NEXT PAGE.
CIRCUIT"?
NO
USE THE SCHEMATIC AS DOES THE DRB REPAIR THE HARNESS
A GUIDE AND WIGGLE MONITOR THE DRB DISPLAY "SOLENOID YES OR CONNECTOR THAT
THE SOLENOID VALVE DISPLAY. VALVE CONTROLLER CAUSED THE CODE TO
CONNECTOR & HARNESS. SHORT CIRCUIT"? SET.*
FIG.1
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-80ACONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY OFF. KEY ON. ERASE CODES.
TEST TC-80A DISCONNECT THE DOES THE DRB DISPLAY YES REPLACE THE FUEL
CONTINUED FROM FUEL PUMP ASSEMBLY "FUEL TIMING PUMP ASSEMBLY.*
PREVIOUS PAGE. CONNECTOR.** SOLENOID CONTROLLER
OPEN CIRCUIT"?
NO
KEY OFF.
DISCONNECT THE ECM REMOVE THE DIESEL
HARNESS POWER RELAY.
CONNECTORS.**
WITH A JUMPER WIRE, KEY ON. USING A REPAIR THE FUEL
CONNECT DIESEL POWER VOLTMETER MEASURE IS THE VOLTAGE YES TIMING SOLENOID
RELAY CONN. CAVITIES THE FUEL TIMING ABOVE 1.0 VOLTS? CONTROL CIRCUIT
30 AND 87 (IN PDC). SOLENOID CONTROL FOR A SHORT TO
FIG.1 CKT. FIG.2 VOLTAGE.*
NO
NOTE: BEFORE
REPLACING THE ECM, DID THE FUEL YES REPLACE THE ENGINE
PERFORM TEST NTC-3A INJECTION PUMP CONTROL MODULE.*
TO CHECK INTERNAL PASS TEST NTC-3A?
FUEL PUMP CIRCUITRY.
NO
REPLACE THE FUEL
INJECTION PUMP
ASSEMBLY.*
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TEST TC-81ACONTINUED - REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-81A KEY OFF.
CONTINUED FROM DISCONNECT THE ECT
THE PREVIOUS SENSOR HARNESS
PAGE. CONNECTOR.**
KEY ON. MEASURE THE ECT REPAIR THE ECT
SIGNAL CIRCUIT. IS THE VOLTAGE YES SENSOR SIGNAL CKT
USE A VOLTMETER IN ABOVE 5.5 VOLTS? FOR A SHORT TO
THE FOLLOWINGVOLTAGE.* IF OK,
STEP. FIG.1 REPLACE THE ECM.*
NO
CONNECT A JUMPER WITH THE DRB, READ REPLACE THE ENGINE
BETWEEN THE ECT THE ENGINE COOLANT IS THE VOLTAGE YES COOLANT
SENSOR SIGNAL AND TEMPERATURE SENSOR BELOW 1.0 VOLT? TEMPERATURE
SENSOR GROUND CKT. VOLTAGE. SENSOR.*
FIG.1
NO
MOVE THE JUMPER WITH THE DRB, READ
WIRE FROM THE THE ENGINE COOLANT IS THE VOLTAGE YES REPAIR THE OPEN
SENSOR GROUND TO TEMPERATURE SENSOR BELOW 1.0 VOLT? SENSOR GROUND
AN ENGINE GROUND. VOLTAGE. CIRCUIT.*
FIG.1
NO
KEY OFF.
DISCONNECT THE ECM USE AN OHMMETER IN
HARNESS THE FOLLOWING
CONNECTORS.** STEP.
MEASURE THE ENGINE
COOLANT TEMEPERATURE IS THE RESISTANCE YES REPLACE THE ENGINE
SENSOR SIGNAL BELOW 5.0 OHMS? CONTROL MODULE.*
CIRCUIT.
FIG.2
NO
REPAIR THE OPEN
ENGINE COOLANT
TEMPERATURE SENSOR
SIGNAL CIRCUIT.*
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TEST TC-82ACONTINUED - REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC LOW
EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-82A DISCONNECT THE
CONTINUED FROM ENGINE COOLANT
THE PREVIOUS TEMPERATURE SENSOR
PAGE. HARNESS
CONNECTOR.**
WITH THE DRB, READ IS THE ENGINE REPLACE THE ENGINE
ENGINE COOLANT COOLANT YES COOLANT
TEMPERATURE SENSOR TEMPERATURE SENSOR TEMPERATURE
VOLTAGE. VOLTAGE ABOVE 4.0 SENSOR.*
VOLTS?
NO
KEY OFF. USING AN OHMMETER, REPAIR THE SENSOR
DISCONNECT THE ECM MEASURE BETWEEN THE IS THE RESISTANCE YES SIGNAL CIRCUIT FOR
HARNESS SENSOR SIGNAL BELOW 5.0 OHMS? A SHORT TO
CONNECTORS.** CIRCUIT AND GROUND. GROUND.*
FIG.1
NO
WITH AN OHMMETER SENSOR SIGNAL REPAIR THE ECT
MEASURE THE CIRCUIT AND THE IS THE RESISTANCE YES SENSOR SIGNAL
RESISTANCE BETWEEN SENSOR GROUND BELOW 5.0 OHMS? CIRCUIT FOR A SHORT
THE ENGINE COOLANT CIRCUIT. TO THE ECT SENSOR
TEMPERATURE... FIG.1 GROUND CIRCUIT.*
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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