relay CHRYSLER CARAVAN 2000 Manual PDF

TEST NTC-10BCHECKING THE FUEL HEATER AND THE CRANKCASE VENT HEATER
Perform TEST NTC-10A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST
NTC-10B. TURN IGNITION OFF.
REPLACE FUSE #16.
NO
TURN IGNITION ON IS THE FUSE OPEN? TEST COMPLETE.*
AND INSPECT FUSE
#16.
YES
CONNECT A JUMPER
REMOVE FUEL HEATER WIRE ACROSS FUEL
RELAY. HEATER RELAY
CAVITIES 30 & 87
(IN PDC). FIG. 1
REPLACE FUSE #6 NO REPLACE THE FUEL
IS THE FUSE OPEN? HEATER RELAY.*
TURN IGNITION ON.
YES
KEY OFF. REPLACE FUSE #16 AND
TURN IGNITION ON. NO REPLACE THE FUEL
DISCONNECT THE IS THE FUSE OPEN? HEATER.*
FUEL HEATER INSPECT FUSE #16.
HARNESS CONNECTOR.
YES
KEY OFF. REPLACE FUSE #16 AND
DISCONNECT THE TURN IGNITION ON. NO REPLACE THE
CRANKCASE VENT IS THE FUSE OPEN? CRANKCASE VENT
HEATER HARNESS INSPECT FUSE #16. HEATER.*
CONNECTOR.
YES
REPAIR THE FUEL
HEATER RELAY
OUTPUT CIRCUIT FOR
A SHORT TO
GROUND.*
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TEST NTC-11ACONTINUED - CHECKING RADIATOR FAN OPERATION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST NTC-11A
CONTINUED FROM
THE PREVIOUS TURN IGNITION OFF.
PAGE.
KEY ON. REPAIR SHORT TO
REMOVE RAD FAN DOES THE LEFT SIDE YES GROUND IN RAD FAN
RELAY #1.** USING THE DRB, RAD FAN CYCLE ON GROUND CKT. BETWEEN
ACTUATE LOW SPEED AND OFF? LEFT SIDE RAD FAN
RAD FAN. AND RELAY #1*
NO
KEY OFF. USE AN BETWEEN RAD FAN
OHMMETER IN THE RELAY #1 TERMINALS IS THE RESISTANCE YES REPLACE THE RAD
FOLLOWING STEPS. 30 AND 87. BELOW 5.0 OHMS? FAN RELAY #1.*
MEASURE THE
RESISTANCE... FIG.1
NO
DISCONNECT THE MEASURE RESISTANCE REPAIR THE SHORT
RIGHT SIDE RAD FAN BETWEEN RAD FAN IS THE RESISTANCE YES TO GROUND IN THE
HARNESS RELAY #1 HARNESS BELOW 5.0 OHMS? RAD FAN RELAY #3
CONNECTOR.** CONNECTOR CAVITY 5 OUTPUT CIRCUIT.*
AND GROUND. FIG.2
NO
REPLACE THE RIGHT
SIDE RADIATOR
FAN.*
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TEST NTC-11BCHECKING RADIATOR FAN OPERATION
Perform TEST NTC-11A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
REMOVE THE DIESEL
POWER RELAY.WITH A JUMPER WIRE
CONNECT DIESEL
POWER RELAY CONN
CAVITIES 30 & 87
(IN PDC).
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TEST NTC-11BCONTINUED - CHECKING RADIATOR FAN OPERATION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST NTC-11B
CONTINUED FROM
THE PREVIOUS TURN IGNITION OFF.
PAGE.
TURN IGNITION ON. REPAIR THE OPEN
DISCONNECT RAD FAN USING A VOLTMETER, IS THE VOLTAGE NO FUSED BATTERY SUPPLY
RELAY #3.** MEASURE RELAY ABOVE 10.0 VOLTS? CKT. IF THE FUSE IS
HARNESS CONNECTOR BLOWN, CHECK FOR
CAVITY 8. FIG.1 SHORT TO GROUND.*
YES
CONNECT A JUMPER CAVITIES 2 AND 8.
WIRE ACROSS RAD IS THE RIGHT SIDE NO REPAIR OPEN RAD
FAN RELAY #3 RAD FAN ON? FAN RELAY #3
HARNESSOUTPUT CIRCUIT.*
CONNECTOR... FIG.1
YES
DISCONNECT RAD FAN RAD FAN RLY #1
RELAY #1 AND #3 HARNESS CONN. CAVITY IS THE RESISTANCE NO REPAIR OPEN HIGH
HARNESS CONNECTORS. 6 AND RAD FAN RLY #3 BELOW 5.0 OHMS? SPEED FAN CONTROL
MEASURE RESISTANCE HARNESS CONN. CAVITY CIRCUIT.*
BETWEEN... 6. FIG.1 AND 2
YES
MEASURE RESISTANCE RAD FAN RELAY #3
BETWEEN RAD FAN HARNESS CONNECTOR IS THE RESISTANCE NO REPAIR THE OPEN
RELAY #1 HARNESS CAVITY 4. BELOW 5.0 OHMS? DIESEL POWER RELAY
CONNECTOR CAVITY 4OUTPUT CIRCUIT.*
AND... FIG.1
YES
REPLACE THE RAD
FAN RELAY #3.*
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TEST NTC-11CCHECKING RADIATOR FAN OPERATION
Perform TEST NTC-11A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST
NTC-11C. TURN IGNITION OFF.
USING A VOLTMETER,
DISCONNECT THE RAD MEASURE RAD FAN IS THE VOLTAGE NO REPAIR OPEN
FAN RELAY #2.** RELAY #2 HARNESS ABOVE 11.0 VOLTS? BATTERY SUPPLY
CONNECTOR CAVITY 8. CIRCUIT OR FUSE.*
FIG.1
YES
CONNECT A JUMPER
WIRE ACROSS RAD CAVITIES 8 AND 2. DID THE FANS TURN YES REPLACE RAD FAN
FAN RELAY #2 ON? RELAY #2.*
HARNESS
CONNECTOR... FIG.1
NO
REPAIR RELAY #2
DID THE BATTERY YES OUTPUT CKT. FOR
SUPPLY FUSE BLOW? SHORT TO GROUND OR
SHORTED LEFT SIDE
RAD FAN MOTOR.*
NO
DISCONNECT FAN USE A VOLTMETER TO
MOTOR HARNESS MEASURE FAN MOTOR IS THE VOLTAGE NO REPAIR OPEN RELAY
CONNECTOR.** HARNESS CONNECTOR ABOVE 10.0 VOLTS? #2 OUTPUT
WITH JUMPER STILL CAVITY 4. CIRCUIT.*
CONNECTED... FIG.2
YES
RECONNECT FAN CONNECT A JUMPER REPAIR OPEN CKT
MOTOR HARNESS WIRE BETWEEN GROUND DID LEFT SIDE RAD NO BETWEEN RLY #1 AND
CONNECTOR. AND RAD FAN RELAY #1 FAN TURN ON? LEFT SIDE FAN MTR.*
DISCONNECT RAD FAN HARNESS CONNECTOR IF OK, REPLACE LEFT
RELAY #1.** CAVITY 8. FIG.3 SIDE FAN MTR.
YES
CONTINUE TEST
NTC-11C ON THE
NEXT PAGE.
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TEST NTC-11CCONTINUED - CHECKING RADIATOR FAN OPERATION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST NTC-11C
CONTINUED FROM USE AN OHMMETER IN
THE PREVIOUS THE FOLLOWING
PAGE. STEPS.
MEASURE RESISTANCE
BETWEEN RAD FAN IS THE RESISTANCE NO REPLACE RAD FAN
RELAY #1 TERMINALS BELOW 5.0 OHMS? RELAY #1.*
5 AND 8.
FIG.1
YES
MEASURE RESISTANCE
DISCONNECT THE RAD BETWEEN RIGHT SIDE IS THE RESISTANCE NO REPAIR OPEN RIGHT
FAN MOTOR HARNESS FAN HARNESS BELOW 5.0 OHMS? SIDE RAD FAN MOTOR
CONNECTOR.** CONNECTOR CAVITY 1 GROUND.*
AND GROUND. FIG.2
YES
MEASURE THE BETWEEN THE RAD REPAIR THE OPEN
RESISTANCE OF THE FAN RELAY #1 AND IS THE RESISTANCE NO RIGHT SIDE RAD FAN
RIGHT SIDE RAD FAN THE RIGHT SIDE RAD BELOW 5.0 OHMS? MOTOR SUPPLY
SUPPLY CIRCUIT... FAN MOTOR. FIG.1 CIRCUIT.*
AND 2
YES
REPLACE THE RIGHT
SIDE RAD FAN
MOTOR.*
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TEST NTC-11DCHECKING RADIATOR FAN OPERATION
Perform TEST NTC-11A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST STOP LOW SPEED FAN
NTC-11D. ACTUATION.
KEY OFF.
SUBSTITUTE THE RAD PERFORM THE DO BOTH FANS CYCLE YES REPLACE THE
FAN #1 RELAY WITH "LOW SPEED FAN" ON AND OFF? INITIAL RAD FAN #1
A KNOWN GOOD ACTUATOR TEST. RELAY.*
RELAY.
NO
DISCONNECT THE
DISCONNECT RAD FAN LEFT SIDE FAN
#1 RELAY HARNESS MOTOR HARNESS
CONNECTOR.** CONNECTOR.**
USING AN OHMMETER, REPAIR THE SHORT
MEASURE THE GROUND IS THE RESISTANCE YES TO GROUND BETWEEN
CKT AT CAVITY 8 TO BELOW 10.0 OHMS? THE LEFT SIDE
GROUND. MOTOR AND RAD FAN
FIG.1 #1 REKAY.
NO
DISCONNECT THE USING AN OHMMETER, REPAIR THE RIGHT
RIGHT SIDE FAN MEASURE CAVITY 5 IS THE RESISTANCE YES SIDE FAN SUPPLY
MOTOR HARNESS TO GROUND. BELOW 10.0 OHMS? CIRCUIT FOR A
CONNECTOR.** SHORT TO GROUND.*
FIG.1
NO
CHECK RIGHT SIDE IS ANYTHING
FAN MOTOR FOR PREVENTING THE FAN YES REPAIR AS
BINDING OR DEBRIS MOTOR FROM NECESSARY.
WHICH MAY PREVENT TURNING?
FAN OPERATION.
NO
REPLACE THE RIGHT
SIDE FAN MOTOR.*
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TEST NS-1AREPAIRING A NO CRANK CONDITION
Perform TEST NS-SEL Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
NOTE: BATTERY MUST
START TEST BE FULLY CHARGED
NS-1A. BEFORE DIAGNOSING
A NO-START
CONDITION.
NOTE: BEFORE VEHICLE THEFT DIAGNOSE
CONTINUING, BE (SKIM) SYSTEM FOR ARE ANY CODES YES TROUBLE CODE
SURE TO CHECK DIAGNOSTIC TROUBLE PRESENT? BEFORE
ENGINE SYSTEM CODES. CONTINUING.]
AND...
NO
INSPECT BATTERY
CABLES FOR IS THERE EVIDENCE YES REPAIR AS
TURN IGNITION OFF. CORROSION, OF PROBLEMS? NECESSARY.*
LOOSENESS OR OTHER
PROBLEMS.
NO
TURN IGNITION OFF. KEY ON. WITH A REPAIR THE STARTER
VOLTMETER, MEASURE IS THE VOLTAGE YES RELAY CONTROL
DISCONNECT THE ECM THE STARTER RELAY ABOVE 1.0 VOLT? CIRCUIT FOR A
HARNESS CONTROL CKT. SHORT TO VOLTAGE.*
CONNECTORS.** FIG.1
NO
KEY OFF. USING A FULLY DEPRESS THE
JUMPER WIRE CONNECT CLUTCH PEDAL. DID THE ENGINE YES REPLACE THE ENGINE
THE STARTER RELAY CRANK? CONTROL MODULE.*
CONTROL CKT TO ATTEMPT TO CRANK
GROUND. FIG.1 THE ENGINE.
NO
WITH A VOLTMETER,
DISCONNECT THE MEASURE THE FUSED IS THE VOLTAGE NO REPAIR OPEN FUSED
STARTER RELAY FROM B(+) CIRCUIT. ABOVE 11.6 VOLTS? BATTERY CIRCUIT.*
THE PDC.**
FIG.1
YES
WARNING: THE TRANS WARNING: THE ENGINE BRIEFLY CONNECT A
MUST BE IN NEUTRAL MAY BE CRANKED IN JUMPER WIRE BETWEEN CONTINUE TEST
AND THE PARKING THE NEXT STEP. KEEP THE STARTER RLY NS-1A ON THE
BRAKE MUST BE ON AWAY FROM MOVING OUTPUT AND FUSED NEXT PAGE.
FOR THE NEXT STEP. ENGINE PARTS. B(+) CKTS. FIG.1
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TEST NS-1ACONTINUED - REPAIRING A NO CRANK CONDITION
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
TEST NS-1A
CONTINUED FROM DID THE STARTER YES CONTINUE TEST
THE PREVIOUS MOTOR CRANK THE NS-1A ON THE
PAGE. ENGINE? NEXT PAGE.
NO
DID THE STARTER
YES SOLENOID CLICK NO DISCONNECT THE
WHEN THE JUMPER JUMPER WIRE.
WIRE WAS
CONNECTED?
USING AN OHMMETER, DISCONNECT STARTER
MEASURE THE RELAY OUTPUT WIRE
STARTER RELAY FROM THE STARTER
OUTPUT CIRCUIT. SOLENOID.**
FIG.1 FIG.2
IS THE RESISTANCE NO REPAIR OPEN
BELOW 5.0 OHMS? STARTER RELAY
OUTPUT CKT.*
YES
CHECK THE BATTERY DID EITHER BATTERY
REINSTALL STARTER CABLES FOR HIGH CIRCUIT HAVE A YES REPAIR THE BATTERY
RELAY. RESISTANCE. (USE VOLTAGE DROP CIRCUIT FOR HIGH
SERVICE MANUAL GREATER THAN 0.2 RESISTANCE.*
PROCEDURE) VOLT?
NO
ATTEMPT TO
MANUALLY ROTATE IS THE CRANKSHAFT NO REPAIR ENGINE
THE CRANKSHAFT 360 ABLE TO ROTATE 360 MECHANICAL PROBLEM
DEGREES. DEGREES? AS NECESSARY.*
YES
REPLACE THE
STARTER MOTOR.*
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TEST NS-1ACONTINUED - REPAIRING A NO CRANK CONDITION
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
TEST NS-1A KEY OFF. WITH AN IS THE RESISTANCE
CONTINUED FROM OHMMETER, MEASURE BETWEEN NO REPLACE THE
THE PREVIOUS THE STARTER RELAY 60.0 AND 90.0 STARTER RELAY.*
PAGE. TERMINALS 85 AND 86. OHMS?
FIG.1
YES
KEY ON. USING A AT THE ECM HARNESS REPAIR THE STARTER
VOLTMETER, MEASURE CONNECTOR. IS THE VOLTAGE YES RELAY CONTROL CKT
STARTER RELAY ABOVE 1.0 VOLT? FOR A SHORT TO
CONTROL CKT... VOLTAGE.*
FIG.2
NO
WITH AN OHMMETER, BETWEEN THE ECM
MEASURE RESISTANCE HARNESS CONNECTOR IS THE RESISTANCE YES REPAIR THE OPEN
OF THE STARTER AND THE PDC ABOVE 5.0 OHMS? STARTER RELAY
RELAY CONTROLCONTROL CIRCUIT.*
CIRCUIT... FIG.2
NO
KEY ON. USING A WITH THE CLUTCH
VOLTMETER, MEASURE WHILE DEPRESSING DEPRESSED, IS THE YES REPLACE THE
THE CLUTCH THE CLUTCH. VOLTAGE ABOVE 10.0 STARTER RELAY.*
INTERLOCK SWITCH VOLTS?
CKT AT THE PDC)...
NO
KEY OFF. DISCONNECT MEASURE CLUTCH
THE CLUTCH INTERLOCK INTERLOCK SWITCH IS THE VOLTAGE NO REPAIR OPEN CLUTCH
SWITCH HARNESS HARNESS CONNECTOR ABOVE 10.0 VOLTS? INTERLOCK SWITCH
CONNECTOR. KEY ON. CAVITY 1. BATTERY SUPPLY.*
USING A VOLTMETER... FIG.3
YES
CONNECT A JUMPER PROBE THE CLUTCH
WIRE ACROSS THE INTERLOCK SWITCH IS THE VOLTAGE YES ADJUST OR REPLACE
CLUTCH INTERLOCK OUTPUT CKT. IN THE ABOVE 10.0 VOLTS? THE CLUTCH
SWITCH HARNESS PDC. INTERLOCK SWITCH.*
CONNECTOR. FIG.2
NO
REPAIR OPEN
CIRCUIT BETWEEN
STARTER RELAY AND
CLUTCH INTERLOCK
SWITCH.*
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