fuse CHRYSLER CARAVAN 2000 Service Manual

After-Run- When fused ignition switch output is removed from the ECM cavity 47, the ECM
performs a self-diagnostic check in the following order:
1. Electrical shut-off test
2. Fuel quantity actuator test
3. Monitoring module test
4. Voltage regulator test
5. Main relay test (if tests 1-4 pass)
If any of tests 1-4 fail, the fault is stored in memory, and can be retrieved during the next ignition
cycle using the DRB.
3.2.3 Monitored Circuits
The ECM is able to monitor and identify most driveability related trouble conditions. Some circuits
are directly monitored through ECM feedback circuitry. In addition, the ECM monitors the voltage
state of some circuits and compares those states with expected values. Other systems are
monitored indirectly when the ECM conducts a rationality test to identify problems.
Although most subsystems of the powertrain control module are either directly or indirectly
monitored, there may be occasions when diagnostic trouble codes are not immediately identified.
For a trouble code to set, specific conditions must be met and unless these conditions are
encountered, a code will not set.
3.2.4 SKIS On-Board Diagnostics
The SKIS module has been programmed to transmit and monitor many different coded messages
as well as CCD Bus messages. This monitoring is called ``On-Board Diagnosis''.
Certain criteria must be met for a diagnostic trouble code to be entered into the Sentry Key
Immobilizer Module (SKIM) memory. The criteria may be a range of: input voltage, CCD Bus
messages, or coded messages to the SKIM. If all of the criteria for monitoring a circuit or function
are met and a fault is sensed, a diagnostic trouble code will be stored in the SKIM memory.
3.2.5 SKIS Overview
The Sentry Key Immobilizer System (SKIS) is an immobilizer system designed to prevent
unauthorized vehicle operation. The system consists of a Sentry Key Immobilizer Module (SKIM),
ignition key(s) equipped with a transponder chip, engine controller and body controller. When the
ignition switch is turned on, the SKIM interrogates the ignition key. If the ignition key is ªValidº the
SKIM sends a CCD Bus message to the body controller indicating the presence of a valid ignition
key. The BCM then supplies the ECM with a valid immobilizer signal allowing the engine to
continue to operate.
3.2.6 SKIS Operation
When ignition power is supplied to the SKIM, the SKIM performs an internal self-test. After the
self-test is completed, the SKIM energizes the antenna (this activates the transponder chip) and
sends a challenge to the transponder chip. The transponder chip responds to the challenge by
generating an encrypted response message using the following:
Secret Key þ This is an electronically stored value (identification number) that is unique to each
SKIS. The secret key is stored in the SKIM, BCM and all ignition key transponders.
Challenge þ This is a random number that is generated by the SKIM at each ignition key cycle.
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²Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
²Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 - 1.12 megohms
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100É F
-50 - 600É C
* Ohms cannot be measured if voltage is
present. Ohms can be measured only in a
non-powered circuit.
²Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
²Use caution when measuring voltage above 25v DC or 25v AC.
²The circuit being tested must be protected by a 10A fuse or circuit breaker.
²Use the low current shunt to measure circuits up to 10A. Use the high current clamp to
measure circuits exceeding 10A.
²When testing for the presence of voltage or current, make sure the meter is functioning
correctly. Take a reading of a known voltage or current before accepting a zero reading.
²When measuring current, connect the meter in series with the load.
²Disconnect the live test lead before disconnecting the common test lead.
5.3 Warnings
5.3.1 Vehicle Damage Warnings
Before disconnecting any control module, make sure the ignition is ``off''. Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end)
of the connector. Do not probe a wire through the insulation; this will damage it and eventually
cause it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, other codes could be set, making diagnosis of
the original problem more difficult.
5.3.2 Road Testing a Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled.
During the test drive, do not try to read the DRB screen while in motion. Do not hang the
DRB from the rear view mirror or operate it yourself. Have an assistant available to operate
the DRB.
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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-20BREPAIRING - BRAKE SWITCH PLAUSIBILITY WITH REDUNDANT CONTACT
Perform TEST TC-20A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST
TC-20B. TURN IGNITION OFF.
DISCONNECT THE KEY ON. USING A
BRAKE LAMP SWITCH VOLTMETER, MEASURE IS THE VOLTAGE NO CONTINUE TEST
HARNESS HARNESS CONNECTOR ABOVE 9.0 VOLTS? TC-20B ON THE
CONNECTOR.** CAVITY 1. NEXT PAGE.
FIG.1
YES
CONNECT A FUSEDREPAIR THE
JUMPER WIRE (5 AMP),YES SECONDARY BRAKE SW
ACROSS BRAKE LAMP CHECK THE FUSE. DID FUSE OPEN? SENSE CIRCUIT FOR
SWITCH HARNESS CONN A SHORT TO
CAVITIES 1 AND 2. VOLTAGE.*
NO
DID THE DRB
DISPLAY CHANGE YES ADJUST OR REPLACE
FROM "PRESSED" TO THE BRAKE LAMP
"RELEASED"? SWITCH.*
NO
KEY OFF. BRAKE LAMP SWITCH REPAIR THE OPEN
USING AN OHMMETER, HARNESS CONNECTOR IS THE RESISTANCE NO SECONDARY BRAKE
MEASURE THE CAVITY 2 AND GROUND. BELOW 5.0 OHMS? LAMP SWITCH GROUND
RESISTANCE CIRCUIT.*
BETWEEN... FIG.1
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-91ACONTINUED - REPAIRING - VEHICLE SPEED SENSOR TROUBLE CODES
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY OFF.
TEST TC-91A
CONTINUED FROM DISCONNECT THE VSS
PREVIOUS PAGE. HARNESS
CONNECTOR.**
USING A VOLTMETER, REPAIR THE
MEASURE THE FUSED IS THE VOLTAGE NO IGNITION SWITCH
TURN IGNITION ON. IGNITION SWITCH ABOVE 10.0 VOLTS? OUTPUT CIRCUIT FOR
OUTPUT CKT. AN OPEN OR SHORT
FIG.1 TO GROUND.*
YES
USING A VOLTMETER,
MEASURE THE VSS IS THE VOLTAGE NO CONTINUE TEST
SIGNAL CIRCUIT. BETWEEN TC-91A ON THE
4.0 AND 6.0 VOLTS? NEXT PAGE.
FIG.1
YES
KEY OFF. USING AN OHMMETER,
MEASURE RESISTANCE IS THE RESISTANCE NO REPAIR THE OPEN
DISCONNECT THE ECM OF SENSOR GROUND CKT BELOW 5.0 OHMS? SENSOR GROUND
HARNESS BETWEEN ECM AND VSS. CIRCUIT.*
CONNECTORS.** FIG.2
YES
PERFORM TEST
TC-91B.
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TEST NTC-2ACONTINUED - CHECKING GLOW PLUG OPERATION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
REPAIR THE OPEN
FUSED B (+)
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TEST NTC-4ACHECKING THE PCM POWER AND GROUNDS
Perform TEST NTC-1A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
NOTE: THE BATTERY
START TEST MUST BE FULLY
NTC-4A. CHARGED TO PERFORM
THIS TEST.
TURN IGNITION OFF. WITH AN OHMMETER,
DISCONNECT THE ECM MEASURE ECM IS THE RESISTANCE NO REPAIR THE OPEN
HARNESS HARNESS CONNECTOR BELOW 5.0 OHMS FOR GROUND CIRCUIT.*
CONNECTORS.** CAVITIES 1 AND 27 ALL MEASUREMENTS?
TO GROUND. FIG.1
YES
PROBE DIESEL POWER
USE A TEST LIGHT RELAY CONNECTOR DOES THE TEST NO REPAIR OPEN
IN THE FOLLOWING CAVITY (PDC) 3(30). LIGHT ILLUMINATE BATTERY SUPPLY TO
STEPS. BRIGHTLY? RELAY.
FIG.2
YES
REMOVE THE DIESEL 3(30) AND 5(87). DOES THE TEST
POWER RELAY. CONNECT WITH A TEST LIGHT, LIGHT ILLUMINATE NO REPAIR OPEN DIESEL
A JUMPER WIRE ACROSS PROBE ECM HARNESS BRIGHTLY FOR EACH POWER RELAY OUTPUT
RELAY CONNECTOR CONNECTOR CAVITIES CAVITY? CIRCUIT.*
(PDC) CAVITIES... 2 AND 28. FIG.2
YES
WITH A TEST LIGHT,
PROBE ECM HARNESS DOES THE TEST NO REPAIR THE OPEN
TURN IGNITION ON. CONNECTOR CAVITY 47. LIGHT ILLUMINATE FUSED IGNITION
BRIGHTLY? SWITCH CIRCUIT.*
FIG.1
YES
ECM GROUND
AND POWER
CIRCUITS ARE
OK. TEST
PASSED.
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TEST NTC-10ACHECKING THE FUEL HEATER AND THE CRANKCASE VENT HEATER
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
START TEST YES PERFORM TEST
NTC-10A. INSPECT FUSE #16 IS THE FUSE OPEN? NTC-10B.
IN THE PDC.
NO
USING A TEST
REMOVE THE FUEL LIGHT, PROBE RELAY IS THE TEST LIGHT NO REPLACE THE POWER
HEATER RELAY.** CONNECTOR CAVITY ON? DISTRIBUTION
30 (IN PDC). CENTER.*.
FIG. 1
YES
USING A TEST REPAIR THE FUSED
LIGHT, PROBE FUSED IS THE TEST LIGHT NO IGNITION SWITCH
TURN IGNITION ON. IGNITION SW OUTPUT ON? OUTPUT CIRCUIT FOR
CKT (IN PDC). AN OPEN OR SHORT
FIG. 1 TO GROUND.*
YES
WITH IGNITION RELAY CONNECTOR
STILL ON, CONNECT CAVITIES 85 AND 86 IS THE TEST LIGHT NO REPAIR THE OPEN
A TEST LIGHT (IN PDC). ON? RELAY GROUND
ACROSS...CIRCUIT.*
FIG. 1
YES
KEY OFF. DISCONNECT THE
FUEL HEATER AND CONTINUE TEST
INSTALL THE FUEL CRANKCASE VENT TURN IGNITION ON. NTC-10A ON THE
HEATER RELAY. HEATER HARNESS NEXT PAGE.
CONNECTORS.**
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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-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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