relay CHRYSLER CARAVAN 2000 Workshop Manual

TEST TC-54AREPAIRING - GLOW RELAY #2 CONTROLLER SHORT CIRCUIT
Perform TEST DTC Before Proceeding
FIG.1
FIG.2
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TEST TC-54AREPAIRING - GLOW RELAY #2 CONTROLLER SHORT CIRCUIT
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST WITH THE DRB, IS THE GLOW PLUG NO CONTINUE
TC-54A. ACTUATE GLOW PLUG #2 RELAY CLICKING? TEST-54A ON THE
#2 RELAY. NEXT PAGE.
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
GLOW #2 RELAY TO THE GLOW PLUG #2 INTERRUPT THE WIGGLING CAUSED
THE 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-54ACONTINUED - REPAIRING - GLOW RELAY #2 CONTROLLER SHORT CIRCUIT
FIG.1
FIG.2
FIG.3
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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-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-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-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-76AREPAIRING - SMART START RELAY SHORT CIRCUIT
Perform TEST DTC Before Proceeding
FIG.1
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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-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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