fuel pump CHRYSLER CARAVAN 2000 Service Manual

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

TEST TC-22ACONTINUED - REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-22A DISCONNECT THE
CONTINUED FROM FUEL INJECTION
PREVIOUS PAGE. PUMP HARNESS
CONNECTOR.**
UES AN OHMMETER IN FUEL INJECTION PUMP IS THE RESISTANCE
THE FOLLOWING CONNECTOR (PUMP BETWEEN NO REPLACE THE FUEL
STEPS. MEASURE THE SIDE) CAVITIES 1 AND 4.9 AND 6.5 OHMS FOR INJECTION PUMP
RESISTANCE 2 AND ALSO 2 AND 3. EACH MEASUREMENT? ASSEMBLY.*
ACROSS... FIG.1
YES
MEASURE THE IS THE RESISTANCE
RESISTANCE BETWEEN BELOW 5.0 OHMS FOR YES REPLACE THE FUEL
GROUND AND FUEL PUMP ANY OF THE INJECTION PUMP
CONNECTOR CAVITIES MEASUREMENTS? ASSEMBLY.*
1, 2 AND 3.
NO
MEASURE RESISTANCE IS THE RESISTANCE REPAIR THE SHORT
DISCONNECT THE ECM BETWEEN GND AND ECM BELOW 5.0 OHMS FOR YES TO GROUND IN THE
HARNESS CONNECTOR CAVITIES ANY OF THE CKT(S) THAT
CONNECTOR.** 56, 57 AND 58. MEASUREMENTS? MEASURED LESS THAN
FIG.1 5.0 OHMS.*
NO
MEASURE THE 56 AND 57, IS THE RESISTANCE REPAIR THE
RESISTANCE BETWEEN 56 AND 58, BELOW 5.0 OHMS FOR YES CIRCUITS SHORTED
ECM HARNESS 57 AND 58. ANY OF THE TOGETHER THAT HAD
CONNECTOR MEASUREMENTS? RESISTANCE BELOW
CAVITIES... FIG. 2 5.0 OHMS.*
NO
PERFORM THE ECM-56 TO INJ.PUMP-1 DID ANY OF THE REPAIR THE
FOLLOWING RESISTANCE TESTS MEASURE YES CIRCUIT(S)THAT
MEASUREMENTS FROM ECM-57 TO INJ.PUMP-2 RESISTANCE ABOVE MEASURED ABOVE 5.0
THE ECM TO THE FUEL 5.0 OHMS? OHMS FOR AN OPEN.*
INJ. PUMP. FIG.2 ECM-58 TO INJ.PUMP-3
NO
REPLACE THE ENGINE
CONTROL MODULE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
101
ProCarManuals.com

TEST TC-23AREPAIRING - CONTROL SLEEVE SENSOR START END POSITION NOT ATTAINED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: IF OTHER TURN IGNITION ON.
START TEST DTC'S ARE PRESENT,
TC-23A. DIAGNOSE OTHER USING THE DRB,
DTC'S BEFORE ERASE CODES.
CONTINUING.
PERFORM SEVERAL
DRIVE CYCLES TURNING BETWEEN EACH DRIVE
THE IGNITION OFF FOR CYCLE.
AT LEAST 10
SECONDS...
DOES THE DRB
USING THE DRB, DISPLAY "CONTROL NO
READ TROUBLE SLEEVE SENSOR TEST COMPLETE.*
CODES. START END POSITION
NOT ATTAINED"?
YES
PERFORM SEVERAL
REPLACE THE FUEL DRIVE CYCLES TURNING BETWEEN EACH DRIVE
INJECTION PUMP THE IGNITION OFF FOR CYCLE.
ASSEMBLY. AT LEAST 10
SECONDS...
DOES THE DRB
USING THE DRB, DISPLAY "CONTROL NO
READ TROUBLE SLEEVE SENSOR TEST COMPLETE.*
CODES. START END POSITION
NOT ATTAINED"?
YES
REPLACE THE ENGINE
CONTROL MODULE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
103
ProCarManuals.com

TEST TC-24AREPAIRING - CONTROL SLEEVE SENSOR STOP END POSITION NOT ATTAINED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: IF OTHER TURN IGNITION ON.
START TEST DTC'S ARE PRESENT,
TC-24A. DIAGNOSE OTHER USING THE DRB,
DTC'S BEFORE ERASE CODES.
CONTINUING.
PERFORM SEVERAL
DRIVE CYCLES TURNING BETWEEN EACH DRIVE
THE IGNITION OFF FOR CYCLE.
AT LEAST 10
SECONDS...
DOES THE DRB
USING THE DRB, DISPLAY "CONTROL NO
READ TROUBLE SLEEVE SENSOR STOP TEST COMPLETE.*
CODES. END POSITION NOT
ATTAINED"?
YES
PERFORM SEVERAL
REPLACE THE FUEL DRIVE CYCLES TURNING BETWEEN EACH DRIVE
INJECTION PUMP THE IGNITION OFF FOR CYCLE.
ASSEMBLY. AT LEAST 10
SECONDS...
DOES THE DRB
USING THE DRB, DISPLAY "CONTROL NO
READ TROUBLE SLEEVE SENSOR STOP TEST COMPLETE.*
CODES. END POSITION NOT
ATTAINED"?
YES
REPLACE THE ENGINE
CONTROL MODULE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
105
ProCarManuals.com

TEST TC-43AREPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR DEVIATION COLD
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST USING THE DRB,
TC-43A. ERASE CODES.
TURN IGNITION OFF. DOES THE DRB
WAIT 10 SECONDS. WITH THE DRB, READ DISPLAY "FUEL YES CONTINUE TEST
ATTEMPT TO START CODES. QUANTITY ACTUATOR TC-43A ON THE
AND IDLE THE NEG. DEVIATION NEXT PAGE.
ENGINE. COLD"?
NO
USING THE SCHEMATIC, DOES THE DRB REPAIR THE HARNESS
WIGGLE THE FUEL DISPLAY "FUEL YES OR CONNECTOR THAT
INJECTION PUMP QUANTITY ACTUATOR CAUSED THE TROUBLE
CONNECTOR & HARNESS. NEG. DEVIATION CODE TO SET.*
FIG.1 COLD"?
NO
AT THIS TIME, THE USING A SCHEMATIC
CONDITION REQUIRED AS A GUIDE, WERE ANY PROBLEMS YES REPAIR AS
TO SET THE CODE IS INSPECT THE WIRING FOUND? NECESSARY.*
NOT PRESENT. AND CONNECTORS.
FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
161
ProCarManuals.com

TEST TC-43ACONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR
DEVIATION COLD
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-43A DISCONNECT THE
CONTINUED FROM FUEL INJECTION
PREVIOUS PAGE. PUMP CONNECTOR.**
USING AN OHMMETER CONNECTOR TO
MEASURE CAVITY 8 GROUND ON THE FUEL IS THE RESISTANCE YES REPLACE THE FUEL
OF THE FUEL PUMP INJECTION PUMP, BELOW 5.0 OHMS? INJECTION PUMP
ASSEMBLY... HARNESS SIDE. ASSEMBLY.*
FIG.1
NO
USING AN OHMMETER IS THE RESISTANCE REPAIR THE SHORT
DISCONNECT THE ECM MEASURE THE BELOW 10.0 FOR ANY YES TO GROUND ON THE
HARNESS RESISTANCE TO GROUND OF THE MEASUREMENTS? FUEL QUANTITY
CONNECTORS.** AT ECM CAVITIES 59, ACTUATOR CONTROL
66 AND 80. FIG.2 CIRCUIT.*
NO
NOTE: BEFORE
REPLACING THE 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.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
163
ProCarManuals.com

TEST TC-44ACONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR
DEVIATION WARM
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-44A DISCONNECT THE
CONTINUED FROM FUEL INJECTION
PREVIOUS PAGE. PUMP CONNECTOR.**
USING AN OHMMETER THE CASE OF THE FUEL
MEASURE CAVITY 8 INJECTION PUMP. IS THE RESISTANCE YES REPLACE THE FUEL
OF THE FUEL PUMP BELOW 5.0 OHMS? INJECTION PUMP
ASSEMBLY CONNECTORASSEMBLY.*
TO... FIG.1
NO
USING AN OHMMETER IS THE RESISTANCE REPAIR THE SHORT
DISCONNECT THE ECM MEASURE THE BELOW 10.0 OHMS YES TO GROUND ON THE
HARNESS RESISTANCE TO GROUND FOR ANY OF THE FUEL QUANTITY
CONNECTORS.** AT ECM CAVITIES 59, MEASUREMENTS? ACTUATOR CONTROL
66 AND 80. FIG.2 CIRCUIT.*
NO
NOTE: BEFORE
REPLACING THE 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.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
167
ProCarManuals.com

TEST TC-45ACONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR POS. GOVERNOR
DEVIATION COLD
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
CHECK FOR RECENT
TEST TC-45A REPLACEMENT OR
CONTINUED FROM MOVEMENT OF THE
PREVIOUS PAGE. FUEL INJECTION
PUMP ASSEMBLY.
NOTE: AN
IMPROPERLY TIMED WAS THE FUEL YES RESET FUEL
FUEL INJECTION INJECTION PUMP INJECTION PUMP TO
PUMP WILL CAUSE MOVED OR REPLACED? ENGINE TIMING.
THIS CODE TO SET.
NO
INSPECT THE FUEL
SYSTEM FOR AT THE FUEL TANK WAS A RESTRICTION YES REPAIR AS
RESTRICTIONS AT THE MODULE. FOUND? NECESSARY.*
DELIVERY LINES,
FILTER AND....
NO
REPLACE THE FUEL START AND OPERATE
INJECTION PUMP THE ENGINE BETWEEN DOES THE DRB YES REPLACE THE ENGINE
ASSEMBLY. IDLE AND 3500 RPM DISPLAY THIS CODE? CONTROL MODULE.*
USING THE DRB, WHILE MONITORING
ERASE CODES. THE DRB DISPLAY.
NO
TEST COMPLETE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
171
ProCarManuals.com

TEST TC-46ACONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR POS. GOVERNOR
DEVIATION WARM
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
CHECK FOR RECENT
TEST TC-46A REPLACEMENT OR
CONTINUED FROM MOVEMENT OF THE
PREVIOUS PAGE. FUEL INJECTION
PUMP ASSEMBLY.
NOTE: AN
IMPROPERLY TIMED WAS THE FUEL YES RESET FUEL
FUEL INJECTION INJECTION PUMP INJECTION PUMP TO
PUMP WILL CAUSE MOVED OR REPLACED? ENGINE TIMING.
THIS CODE TO SET.
NO
INSPECT THE FUEL
SYSTEM FOR AT THE FUEL TANK WAS A RESTRICTION YES REPAIR AS
RESTRICTIONS AT THE MODULE. FOUND? NECESSARY.*
DELIVERY LINES,
FILTER AND....
NO
REPLACE THE FUEL START AND OPERATE
INJECTION PUMP THE ENGINE BETWEEN DOES THE DRB YES REPLACE THE ENGINE
ASSEMBLY. IDLE AND 3500 RPM DISPLAY THIS CODE? CONTROL MODULE.*
USING THE DRB, WHILE MONITORING
ERASE CODES. THE DRB DISPLAY.
NO
TEST COMPLETE.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
175
ProCarManuals.com

TEST TC-47ACONTINUED - REPAIRING - FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-47A KEY OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS FUEL INJECTION
PAGE. PUMP HARNESS
CONNECTOR.**
KEY ON. MEASURE THE FUEL REPAIR THE FUEL
TEMP SENSOR SIGNAL IS THE VOLTAGE YES TEMP SENSOR SIGNAL
USE A VOLTMETER IN CIRCUIT. ABOVE 5.5 VOLTS? CKT FOR A SHORT TO
THE FOLLOWINGVOLTAGE. IF OK,
STEP. FIG.1 REPLACE THE ECM.*
NO
CONNECT A JUMPER DOES THE DRB
BETWEEN THE FUEL WITH THE DRB, DISPLAY "FUEL YES REPLACE THE FUEL
TEMPERATURE SENSOR ERASE AND THEN TEMPERATURE SENSOR INJECTION PUMP
SIGNAL AND SENSOR READ CODES. LOW EXCEEDED"? ASSEMBLY.*
GROUND CKT. FIG.1
NO
MOVE THE JUMPER DOES THE DRB
WIRE FROM THE WITH THE DRB, READ DISPLAY "FUEL YES REPAIR THE OPEN
SENSOR GROUND TO CODES. TEMPERATURE SENSOR SENSOR GROUND
AN ENGINE GROUND. LOW EXCEEDED"? CIRCUIT.*
NO
KEY OFF. DISCONNECT MEASURE THE FUEL REPAIR THE OPEN
THE ECM HARNESS TEMPERATURE SENSOR IS THE RESISTANCE NO FUEL TEMPERATURE
CONNECTORS.** SIGNAL CIRCUIT. BELOW 5.0 OHMS? SENSOR SIGNAL
CIRCUIT.*
USING AN OHMMETER... FIG.2
YES
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.*
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
179
ProCarManuals.com