battery CHRYSLER CARAVAN 2000 Service Manual

TABLE OF CONTENTS - Continued
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES...........................19
7.1GENERAL TROUBLESHOOTING....................................19
TROUBLE CODE TESTS
TEST DTCCHECKING FOR DIAGNOSTIC TROUBLE CODES.............20
TC-1AREPAIRING - A/C CONTROL SHORT CIRCUIT.................22
TC-2AREPAIRING - A/C CONTROL OPEN CIRCUIT..................28
TC-3AREPAIRING - A/C SYSTEM PRESSURE SIGNAL HIGH
EXCEEDED..............................................34
TC-4AREPAIRING - A/C SYSTEM PRESSURE SIGNAL LOW
EXCEEDED..............................................38
TC-5AREPAIRING - A/C SYSTEM PRESSURE SUPPLY HIGH
EXCEEDED..............................................42
TC-6AREPAIRING - A/C SYSTEM PRESSURE SUPPLY LOW
EXCEEDED..............................................46
TC-7AREPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE
CODES.................................................50
TC-14AREPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED.......60
TC-15AREPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH
EXCEEDED..............................................62
TC-16AREPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW
EXCEEDED..............................................70
TC-17AREPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY HIGH
EXCEEDED..............................................74
TC-18AREPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY LOW
EXCEEDED..............................................78
TC-19AREPAIRING - TURBOCHARGER BOOST SENSOR PLAUSIBILITY.82
TC-20AREPAIRING - BRAKE SWITCH PLAUSIBILITY WITH REDUNDANT
CONTACT...............................................86
TC-21AREPAIRING - CLUTCH SIGNAL PLAUSIBILITY.................94
TC-22AREPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH
EXCEEDED..............................................98
TC-23AREPAIRING - CONTROL SLEEVE SENSOR START END POSITION
NOT ATTAINED..........................................102
TC-24AREPAIRING - CONTROL SLEEVE SENSOR STOP END POSITION
NOT ATTAINED..........................................104
TC-25AREPAIRING - CRUISE STATUS INDICATOR LAMP SHORT
CIRCUIT................................................106
TC-26AREPAIRING - DIAGNOSTIC LAMP OPEN CIRCUIT............110
TC-27AREPAIRING - DIAGNOSTIC LAMP SHORT CIRCUIT...........114
TC-30AREPAIRING - DIESEL POWER RELAY SHUTS OFF TOO EARLY .118
TC-31AREPAIRING - DIESEL POWER RELAY SHUTS OFF TOO LATE . .122
TC-33AREPAIRING - EGR OPEN CIRCUIT.........................126
TC-34AREPAIRING - EGR SHORT CIRCUIT........................130
TC-35AREPAIRING - ENGINE SPEED SENSOR DYNAMIC
PLAUSIBILITY...........................................134
TC-36AREPAIRING - ENGINE SPEED SENSOR OVERSPEED
RECOGNITION..........................................138
TC-38AREPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY .140
TC-39AREPAIRING - FAN CONTROL OPEN CIRCUIT FAN 1..........144
TC-40AREPAIRING - FAN CONTROL OPEN CIRCUIT FAN 2..........148
TC-41AREPAIRING - FAN CONTROL SHORT CIRCUIT FAN 1.........152
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3.3.2 Intermittent Code
A diagnostic trouble code that is not there every time the engine control module/SKIM checks the
circuit is an ªintermittentº code. Most intermittent codes are caused by wiring or connector
problems. Defects that come and go like this are the most difficult to diagnose; they must be
looked for under specific conditions that cause them. The following checks may assist you in
identifying a possible intermittent problem:
²Visually inspect related wire harness connectors. Look for broken, bent, pushed out, or
corroded terminals.
²Visually inspect the related harnesses. Look for chafed, pierced, or partially broken wire.
²Refer to any hotlines or technical service bulletins that may apply.
NOTE: Electromagnetic (radio) interference can cause an intermittent system malfunction. This
interference can interrupt communication between the ignition key transponder and the SKIM.
3.3.3 Reset Counter
The reset counter counts the number of times the vehicle has been started since codes were last
set, erased, or the battery was disconnected. The reset counter will count up to 255 start counts.
The number of starts helps determine when the trouble code actually happened. This is recorded
by the ECM and can be viewed on the DRB as the RESET COUNTER.
When there are no trouble codes stored in memory, the DRB will display ªNO TROUBLE CODES
FOUNDº and the reset counter will show ªRESET COUNT = XXX.º
3.3.4 ECM Diagnostic Trouble Codes
A/C CONTROL SHORT CIRCUIT
A/C CONTROL OPEN CIRCUIT
A/C SYSTEM PRESSURE SIGNAL HIGH EXCEEDED
A/C SYSTEM PRESSURE SIGNAL LOW EXCEEDED
A/C SYSTEM PRESSURE SUPPLY HIGH EXCEEDED
A/C SYSTEM PRESSURE SUPPLY LOW EXCEEDED
ACCELERATOR PEDAL SENSOR SIGNAL HIGH EXCEEDED
ACCELERATOR PEDAL SENSOR PLAUSIBILITY
ACCELERATOR PEDAL SENSOR PWG PLAUS WITH LOW IDLE SWITCH
ACCELERATOR PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER
ATMOSPHERIC PRESSURE SENSOR SRC HIGH EXCEEDED
ATMOSPHERIC PRESSURE SENSOR SRC LOW EXCEEDED
BATTERY VOLTAGE SRC HIGH EXCEEDED
BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT
CLUTCH SIGNAL PLAUSIBILITY
CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED
CONTROL SLEEVE SENSOR START END POS. NOT ATTAINED
CONTROL SLEEVE SENSOR STOP END POS. NOT ATTAINED
CRUISE STATUS INDICATOR LAMP SHORT CIRCUIT
DIAGNOSTIC LAMP OPEN CIRCUIT
DIAGNOSTIC LAMP SHORT CIRCUIT
DIESEL POWER RELAY SHUTS OFF TOO EARLY
DIESEL POWER RELAY SHUTS OFF TOO LATE
EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ. (EGR)
EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212
EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM
EEPROM PLAUSIBILITY FUNC. SWITCH WRONG OR MISSING
EEPROM PLAUSIBILITY VER. NUMBER NOT CORRESPONDING
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3.5.1 DRB Does Not Power Up
If the LED's do not light or no sound is emitted at start up, check for loose cable connections or
a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11
volts at DLC cavity 16 is required to adequately power the DRB. Check for proper ground
connection at DLC cavities 4 and 5.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. For
a blank screen, refer to the appropriate diagnostics manual.
3.5.2 Display is Not Visible
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
condition.
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4.8 Lamps and Indicators
The ªCruiseº lamp is controlled by the Body Control Module. The Diagnostic/Glow Plug lamp is
controlled by the Engine Control Module. The ªAlarm Setº lamp is controlled by the SKIM.
5.0 DISCLAIMERS, SAFETY, WARNINGS
5.1 Disclaimers
All information, illustrations, and specifications contained in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any time
without notice.
5.2 Safety
5.2.1 Technician Safety Information
WARNING!!Engines produce carbon monoxide that is odorless, causes slower reaction time,
and can lead to serious injury. When the engine is operating, keep service areas WELL
VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system.
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the
drive wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
When diagnosing a powertrain system problem, it is important to follow approved procedures
where applicable. These procedures can be found in the service manual. Following these
procedures is very important to the safety of individuals performing diagnostic tests.
5.2.2 Vehicle Preparation for Testing
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
5.2.3 Servicing Sub-Assemblies
Some components of the powertrain system are intended to be serviced in assembly only.
Attempting to remove or repair certain system sub-components may result in personal injury
and/or improper system operation. Only those components with approved repair and installation
procedures in the service manual should be serviced.
5.2.4 DRBIIITSafety Information
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to
serious or possibly fatal injury. Carefully read and understand the cautions and the
specification limits.
²Follow the vehicle manufacturer's service specifications at all times.
²Do not use the DRB if it has been damaged.
²Do not use the test leads if the insulation is damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
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TEST DTCCHECKING FOR DIAGNOSTIC TROUBLE CODES
NOTE: The battery must be fully charged for any test in this manual.
1. Attempt to start the engine. Crank for up to 10 seconds if necessary.
2. Connect the DRB to the data link connector. Write down the trouble codes that are displayed.
3. If the DRB displays ``No Response'', go toTEST NS-2A.
4. If the DRB screen is blank or has a DRB error message, go toGeneral Information Section
3.5in this manual.
5. Iftrouble code messagesare displayed, refer to the trouble code list below and on the
following page for the appropriate test.
6. If there are no ECM trouble codes displayed, refer to one of the following:
For Immobilizer problems..................................................SK-1A
For Driveability problems.................................................NTC-1A
For No Start problems....................................................NS-1A
For Speed Control problems...............................................SC-1A
NOTE:For all component locations see General Information Section 4.0 in this manual.
DRB DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYEDDIAGNOSTIC
TESTSCAN
TOOL
AC Control Short CircuitTC-1 P1655
A/C Control Open CircuitTC-2 P1655
A/C System Pressure Signal High Exceeded TC-3 P1695
A/C System Pressure Signal Low Exceeded TC-4 P1695
A/C System Pressure Supply High Exceeded TC-5 P1695
A/C System Pressure Supply Low Exceeded TC-6 P1695
Accelerator Pedal Sensor High Exceeded TC-7 P1515
Accelerator Pedal Sensor PlausibilityTC-7 P1515
Accelerator Pedal Sensor Pwg Plaus With Low Idle Switch TC-7 P1515
Accelerator Pedal Sensor Pwg Plaus With Potentiometer TC-7 P1515
Atmospheric Pressure Sensor SRC High Exceeded ** P1105
Atmospheric Pressure Sensor SRC Low Exceeded ** P1105
Battery Voltage SRC High Exceeded TC-14 P1600
Turbocharger Boost Sensor Signal High Exceeded TC-15 P0235
Turbocharger Boost Sensor Signal Low Exceeded TC-16 P0235
Turbocharger Boost Sensor Supply High Exceeded TC-17 P0235
Turbocharger Boost Sensor Supply Low Exceeded TC-18 P0235
Turbocharger Boost Sensor Plausibility TC-19 P0235
Brake Signal Plaus With Redundant Contact TC-20 P1703
Clutch Signal PlausibilityTC-21 P1740
Control Sleeve Sensor Signal High Exceeded TC-22 P1225
Control Sleeve Sensor Start End Pos. Not Attained TC-23 P1225
Control Sleeve Sensor Stop End Pos. Not Attained TC-24 P1225
Cruise Status Indicator Lamp Short Circuit TC-25 P1665
Diagnostic Lamp Open CircuitTC-26 P1650
Diagnostic Lamp Short CircuitTC-27 P1650
Diesel Power Relay Shuts Off Too Early TC-30 P1625
Diesel Power Relay Shuts Off Too Late TC-31 P1625
EEPROM Plausibility Checksum Error For Adj. ** P1680
EEPROM Plausibility Checksum Error in CC212 ** P1680
EEPROM Plausibility Communication with EEPROM ** P1680
EEPROM Plausibility Func. Switch Wrong or Missing ** P1680
EEPROM Plausibility Ver. Number Not Corresponding ** P1680
EGR Open CircuitTC-33 P0400
EGR Short CircuitTC-34 P0400
Engine Speed Sensor Dynamic Plausibility TC-35 P0725
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TEST TC-14AREPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED
Perform TEST DTC Before Proceeding
FIG.1
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TEST TC-14AREPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
INCREASE ENGINE REPAIR CHARGING
START TEST SPEED TO 2000 RPM. IS THE VOLTAGE YES SYSTEM FOR
TC-14A. MEASURE THE ABOVE 17.0 VOLTS? OVERCHARGING
VOLTAGE AT THE CONDITION.*
BATTERY.
NO
NOTE: PERFORM THE USE THE SCHEMATIC AS REPAIR CHARGING
FOLLOWING STEP A GUIDE AND WIGGLE IS THE VOLTAGE YES SYSTEM FOR
WITH THE ENGINE THE ALTERNATOR ABOVE 17.0 VOLTS? OVERCHARGING
SPEED AT 2000 RPM. CONNECTOR & HARNESS. CONDITION.*
NO
USING THE DRB,
ERASE CODES. RUN USING THE DRB, DOES THE DRB YES REPLACE THE ENGINE
THE ENGINE AT IDLE READ CODES. DISPLAY "BATTERY CONTROL MODULE.*
AND 2500 RPM FOR VOLTAGE HIGH"?
SEVERAL MINUTES.
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.1 CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-20ACONTINUED - REPAIRING - BRAKE SWITCH PLAUSIBILITY WITH REDUNDANT
CONTACT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-20A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS BRAKE LAMP SWITCH
PAGE. HARNESS
CONNECTOR.**
USING A VOLTMETER,
PROBE BRAKE SWITCH IS THE VOLTAGE NO REPAIR OPEN FUSED
HARNESS CONNECTOR ABOVE 9.0 VOLTS? BATTERY SUPPLY
CAVITY 6. CIRCUIT.*
FIG.1
YES
CONNECT A JUMPER
WIRE ACROSS THE DID THE DRB CHANGE YES ADJUST OR REPLACE
BRAKE LAMP FROM "RELEASED" TO THE BRAKE LAMP
HARNESS CONNECTOR "PRESSED"? SWITCH.*
CAV 5 AND 6. FIG.1
NO
KEY ON. USING A AT THE BRAKE LAMP REPAIR THE PRIMARY
VOLTMETER, MEASURE SWITCH HARNESS IS THE VOLTAGE YES BRAKE LAMP SWITCH
THE PRIMARY SWITCH CONNECTOR CAVITY 5. ABOVE 1.0 VOLT? SIGNAL CIRCUIT FOR
SIGNAL VOLTAGE... A SHORT TO
FIG.1 VOLTAGE.*
NO
KEY OFF. USING AN OHMMETER, REPAIR THE OPEN
DISCONNECT THE ECM MEASURE RESISTANCE IS THE RESISTANCE NO PRIMARY BRAKE LAMP
HARNESS OF THE PRIMARY BRAKE BELOW 5.0 OHMS? SWITCH SIGNAL
CONNECTORS.** LAMP SWITCH SIGNAL CIRCUIT.*
CIRCUIT. FIG.2
YES
REPLACE THE ENGINE
CONTROL MODULE.* SW
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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-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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