cruise control 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
ii
ProCarManuals.com

TABLE OF CONTENTS - Continued
TC-86AREPAIRING - TIMING GOVERNING POSITIVE GOVERNOR
DEVIATION.............................................266
TC-91AREPAIRING - VEHICLE SPEED SENSOR TROUBLE CODES. . . .270
TC-94AREPAIRING - VEHICLE THEFT ALARM TROUBLE CODES......280
SENTRY KEY IMMOBILIZER SYSTEM
SK-1AIDENTIFYING SENTRY KEY IMMOBILIZER PROBLEMS........286
SK-2AREPAIRING - PCM STATUS FAILURE.......................290
SK-3AREPAIRING - ROLLING CODE FAILURE.....................294
SK-4AREPAIRING - SERIAL LINK EXTERNAL FAILURE..............298
SK-5AREPAIRING - TRANSPONDER COMMUNICATION FAILURE.....302
SK-6ATRANSPONDER CRC (CYCLIC REDUNDANCY CHECK)
FAILURE...............................................306
SK-7AREPAIRING - TRANSPONDER ID MISMATCH................310
SK-8AREPAIRING - TRANSPONDER RESPONSE MISMATCH........314
SK-9AREPAIRING - VIN MISMATCH..............................318
NO TROUBLE CODE TESTS
NTC-1ANO TROUBLE CODE TEST MENU..........................322
NTC-2ACHECKING GLOW PLUG OPERATION......................324
NTC-3ACHECKING FUEL INJECTION PUMP CIRCUITS...............328
NTC-4ACHECKING THE PCM POWER AND GROUNDS..............330
NTC-5ACHECKING ENGINE COOLANT SENSOR CALIBRATION AND
RADIATOR FAN OPERATION..............................332
NTC-6ACHECKING ACCELERATOR PEDAL POSITION SENSOR
CALIBRATION...........................................334
NTC-7ACHECKING BOOST PRESSURE SENSOR CALIBRATION.......336
NTC-8ACHECKING FUEL TEMPERATURE SENSOR CALIBRATION.....338
NTC-9ACHECKING EGR SYSTEM.................................340
NTC-10ACHECKING THE FUEL HEATER AND THE CRANKCASE VENT
HEATER................................................342
NTC-11ACHECKING RADIATOR FAN OPERATION....................352
NTC-12ACHECKING THE ENGINE MECHANICAL SYSTEMS...........366
NTC-13ACHECKING THE TURBOCHARGER OPERATION..............368
SPEED CONTROL TESTS
SC-1ACHECKING SPEED CONTROL OPERATION..................372
SC-2ACHECKING SPEED CONTROL OPERATION..................376
SC-3ACHECKING SPEED CONTROL OPERATION..................378
SC-4ACHECKING SPEED CONTROL OPERATION..................386
SC-5ACHECKING SPEED CONTROL OPERATION..................388
SC-6ACHECKING CRUISE INDICATOR OPERATION................390
NO START TESTS
NS-SELNO START SELECTION MENU.............................392
NS-1AREPAIRING A NO CRANK CONDITION......................394
NS-2AREPAIRING A NO RESPONSE CONDITION..................400
NS-3AREPAIRING - NO START..................................410
NS-4AREPAIRING A START AND STALL CONDITION................418
NS-5ACHECKING THE ENGINE MECHANICAL SYSTEMS...........420
iv
ProCarManuals.com

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
G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
5
ProCarManuals.com

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.
G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
17
ProCarManuals.com

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
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
20
ProCarManuals.com

TEST TC-25AREPAIRING - CRUISE STATUS INDICATOR LAMP SHORT CIRCUIT
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION ON.
START TEST USING THE DRB,
TC-25A. CLEAR TROUBLE
CODES.
TURN IGNITION ON.
TURN IGNITION OFF. PRESS THE SPEED DID TROUBLE CODE YES CONTINUE TEST
WAIT 30 SECONDS. CONTROL ON/OFF RESET? TC-25A ON NEXT
BUTTON SEVERAL PAGE.
TIMES.
NO
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
KEY ON. WIGGLE THEREPAIR AS
WIRING FROM THE BODY CONTROL DOES DRB DISPLAY YES NECESSARY WHERE
ENGINE CONTROL MODULE. TROUBLE CODE? WIGGLING CAUSED
MODULE TO THE ...FAULT.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
107
ProCarManuals.com

TEST SC-1ACHECKING SPEED CONTROL OPERATION
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
START TEST KEY ON. WITH THE
SC-1A. DRB, SELECT
"SENSOR DISPLAY".
PRESS EACH OF THE PRESSING EACH SWITCH DID EACH SWITCH
CRUISE SWITCH SHOULD RESULT IN A PROVIDE THE NO PERFORM TEST
BUTTONS WHILE VOLTAGE INPUT SHOWN CORRECT VOLTAGE SC-2A.
OBSERVING CRUISE IN FIG.1. INPUT.
SWITCH VOLTS.
YES
WITH THE DRB, DID THE DRB INDICATE
MONITOR THE WHILE PRESSING AND THE CORRECT CHANGE NO PERFORM TEST
PRIMARY AND RELEASING THE OF STATE FROM SC-3A.
SECONDARY BRAKE BRAKE PEDAL. "RELEASED" TO
SWITCH INPUT... "PRESSED".
YES
DID THE DRB INDICATE
WITH THE DRB, WHILE PRESSING AND THE CORRECT CHANGE NO PERFORM TEST
MONITOR THE CLUTCH RELEASING THE OF STATE FROM SC-4A.
SWITCH INPUT. CLUTCH PEDAL. "RELEASED" TO
"PRESSED".
YES
WITH THE DRB,
MONITOR VEHICLE DOES THE DRB NO PERFORM TEST
SPEED WHILE DISPLAY ACCURATE SC-6A.
DRIVING THE VEHICLE SPEED?
VEHICLE.
YES
DRIVE VEHICLE AND ATTEMPT TO SET DID THE SPEED YES
GENERATE A SPEED SPEED CONTROL. CONTROL MAINTAIN TEST COMPLETED.*
ABOVE 35KM/H. SET VEHICLE SPEED?
NO
CONTINUE TEST
SC-1A ON THE
NEXT PAGE.
S
P
E
E
D
C
O
N
T
R
O
L
T
E
S
T
S
373
ProCarManuals.com

TEST SC-2ACHECKING SPEED CONTROL OPERATION
Perform TEST SC-1A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
KEY OFF.
START TEST DISCONNECT THE
SC-2A. CLOCKSPRING
HARNESS
CONNECTOR.**
KEY ON. USING THE A JUMPER WIRE DID THE VOLTAGE
DRB, MONITOR THE ACROSS CLOCKSPRING CHANGE FROM YES REPLACE THE SPEED
CRUISE SWITCH HARNESS CONNECTOR APPROXIMATELY 5.0 CONTROL SWITCHES.*
VOLTAGE WHILE CAVITIES 3 AND 4. VOLTS TO 0 VOLTS?
CONNECTING... FIG.1
NO
KEY ON. PROBE THE REPAIR THE OPEN
USE A VOLTMETER IN CLOCKSPRING IS THE VOLTAGE YES SPEED CONTROL
THE FOLLOWING HARNESS CONNECTOR ABOVE 4.0 VOLTS? SWITCH GROUND
STEP. CAVITY 4. CIRCUIT.*
NO
KEY OFF. USING AN OHMMETER,
DISCONNECT THE ECM MEASURE THE SPEED IS THE RESISTANCE YES REPAIR THE OPEN
HARNESS CONTROL SWITCH ABOVE 5.0 OHMS? SPEED CONTROL
CONNECTORS.** CIRCUIT. SWITCH CIRCUIT.*
FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
S
P
E
E
D
C
O
N
T
R
O
L
T
E
S
T
S
377
ProCarManuals.com

TEST SC-6ACHECKING CRUISE INDICATOR OPERATION
Perform TEST SC-1A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
NOTE: PERFORM TEST
START TEST SC-1A TO VERIFY
SC-6A. PROPER CRUISE
SWITCH OPERATION
BEFORE CONTINUING.
TURN IGNITION ON. MONITOR CRUISE DOES LAMP STATE CHECK CRUISE LAMP
WITH THE DRB SELECT LAMP STATE WHILE CHANGE FROM "ON" YES BULB, REPLACE AS
"BODY" "MIC" PRESSING CRUISE TO "OFF" WHEN NECESSARY. IF OK,
"MONITOR DISPLAY" ON/OFF BUTTON PRESSING THE REPLACE THE
THEN "CCD BUS INFO". SEVERAL TIMES. BUTTON? INSTRUMENT CLUSTER.*
NO
KEY OFF. KEY ON. CONNECT A
DISCONNECT THE ECM JUMPER WIRE BETWEEN IS THE SPEED YES REPLACE THE ENGINE
HARNESS ECM HARNESS CONTROL LAMP ON? CONTROL MODULE.*
CONNECTORS.** CONNECTOR CAVITY 30
AND GROUND. FIG.1
NO
KEY OFF. USING AN OHMMETER, REPAIR SHORT TO
DISCONNECT THE BCM MEASURE RESISTANCE IS THE RESISTANCE YES GROUND ON THE
HARNESS BETWEEN ECM HARNESS BELOW 5.0 OHMS? SPEED CONTROL LAMP
CONNECTORS.** CONNECTOR CAVITY 30 CONTROL CIRCUIT.*
AND GROUND. FIG.1
NO
USING AN OHMMETER
MEASURE THE SPEED IS THE RESISTANCE YES REPAIR OPEN SPEED
CONTROL LAMP ABOVE 5.0 OHMS? CONTROL LAMP
CONTROL CIRCUIT. CONTROL CIRCUIT.*
FIG.2
NO
REPLACE THE BODY
CONTROL MODULE.*
S
P
E
E
D
C
O
N
T
R
O
L
T
E
S
T
S
391
ProCarManuals.com