jump start CHRYSLER CARAVAN 2000 Service Manual

TEST TC-7AREPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE CODES
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY OFF. CONNECT ONE END OF A
START TEST JUMPER WIRE TO ACCEL
TC-7A. DISCONNECT THE ACCEL PEDAL SENSOR HARNESS
PEDAL SENSOR HARNESS CONN CAVITY 3.
CONNECTOR.** FIG.1
KEY ON. USING THE THE JUMPER WIRE TO DOES THE DRB CHANGE
DRB, READ THE ACCEL PEDAL SENSOR BETWEEN "IDLE" TO NO PERFORM TEST
"LOW IDLE SWITCH" HARNESS CONNECTOR "ABOVE IDLE" TC-7B.
INPUT WHILE TAPPING CAVITY 5. WHEN TAPPING THE
THE OTHER END OF... FIG.1 JUMPER WIRE.
YES
REMOVE JUMPER WIRE. MEASURE BETWEEN
GROUND AND THE IS THE VOLTAGE NO PERFORM TEST
USE A VOLTMETER IN 5-VOLT SUPPLY CKT. BETWEEN TC-7C.
THE FOLLOWING STEPS. 4.7 AND 5.3 VOLTS?
FIG.1
YES
MEASURE BETWEEN REPAIR THE SENSOR
SENSOR GROUND IS THE VOLTAGE NO GROUND CIRCUIT FOR
(CAV 8) AND 5-VOLT BETWEEN AN OPEN.
SUPPLY CKT. 4.7 AND 5.3 VOLTS? IF OK, REPLACE THE
FIG.1 ECM.*
YES
MEASURE BETWEEN REPAIR THE SIGNAL
GROUND AND THE IS THE VOLTAGE NO CIRCUIT FOR A
ACCEL PEDAL SENSOR BELOW 0.5 VOLT? SHORT TO VOLTAGE.
SIGNAL CKT. IF OK, REPLACE THE
FIG.1 ECM.*
YES
CONNECT A JUMPER REPAIR THE OPEN
WIRE BETWEEN THE USING THE DRB, IS THE VOLTAGE NO ACCEL PEDAL SENSOR
5-VOLT SUPPLY CKT READ THE ABOVE 4.5 VOLTS? SIGNAL CIRCUIT.
AND ACCEL PEDAL "ACCEL PEDAL VOLTS". IF OK,
SENSOR CKT. FIG.1REPLACE THE ECM.
YES
REMOVE JUMPER KEY ON. WITH THE IS THE VOLTAGE
WIRE. KEY OFF. ACCEL PEDAL AT REST BETWEEN NO REPLACE THE
RECONNECT THE (IDLE), USE THE DRB 0.28 AND 0.38 ACCELERATOR PEDAL
ACCEL PEDAL SENSOR AND READ THE ACCEL VOLTS? POSITION SENSOR.*
HARNESS CONNECTOR. PEDAL SENSOR VOLTS.
YES
CONTINUE TEST
TC-7A ON THE
NEXT PAGE.
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TEST TC-7BREPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE CODES
Perform TEST TC-7A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
WITH JUMPER STILL DOES THE DRB DISPLAY REPAIR THE OPEN
START TEST CONNECTED TO CAVITY CHANGE BETWEEN YES SENSOR GROUND.
TC-7B. 5, TAP THE OTHER END "IDLE" TO "ABOVE IF OK,
OF THE JUMPER TO IDLE" WHEN TAPPING REPLACE THE ECM*
CHASSIS GROUND. THE JUMPER WIRE?
NO
USING A VOLTMETER, REPAIR THE LOW
MEASURE THE LOW IS THE VOLTAGE YES IDLE POSITION
IDLE POSITION ABOVE 5.5 VOLTS? SENSE CIRCUIT FOR
SENSE CKT. A SHORT TO
FIG.1 VOLTAGE.*
NO
TURN IGNITION OFF. USING AN OHMMETER, REPAIR THE LOW
MEASURE BETWEEN IS THE RESISTANCE YES IDLE POSITION
DISCONNECT THE ECM GROUND AND THE LOW BELOW 5.0 OHMS? SENSE CIRCUIT FOR
HARNESS IDLE POSITION A SHORT TO
CONNECTORS.** SENSE CKT. FIG.1 GROUND.*
NO
USING AN OHMMETER,
MEASURE THE LOW IS THE RESISTANCE NO REPAIR THE OPEN
IDLE POSITION BELOW 5.0 OHMS? LOW IDLE POSITION
SENSE CKT. SENSE CIRCUIT.*
FIG.2
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-7CREPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE CODES
Perform TEST TC-7A Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
START TEST DISCONNECT THE ECM
TC-7C. TURN IGNITION OFF. HARNESS
CONNECTORS.**
MEASURE BETWEEN REPAIR THE 5-VOLT
USE AN OHMMETER IN GROUND AND THE IS THE RESISTANCE YES SUPPLY CIRCUIT FOR
THE FOLLOWING 5-VOLT SUPPLY CKT. BELOW 5.0 OHMS? A SHORT TO
STEPS. GROUND.*
FIG.1
NO
EACH GROUND CIRCUIT REPAIR THE 5-VOLT
MEASURE BETWEEN AT ACCEL PEDAL IS THE RESISTANCE YES SUPPLY CIRCUIT FOR
THE 5-VOLT SUPPLY SENSOR HARNESS CONN BELOW 5.0 OHMS? A SHORT TO SENSOR
CIRCUIT AND... CAVITIES 3 AND 8. GROUND.*
FIG.1
NO
WITH A JUMPER WIRE,
REMOVE THE DIESEL CONNECT DIESEL POWER
POWER RELAY.** RELAY CONN. CAVITIES
30 AND 87 (IN PDC).
FIG.2
USING A VOLTMETER, REPAIR THE 5-VOLT
MEASURE THE 5-VOLT IS THE VOLTAGE YES SUPPLY CIRCUIT FOR
TURN IGNITION ON. SUPPLY CKT. ABOVE 1.0 VOLT? A SHORT TO
VOLTAGE.*
FIG.1
NO
USING AN OHMMETER,
MEASURE THE IS THE RESISTANCE NO REPAIR THE OPEN
TURN IGNITION OFF. RESISTANCE OF THE BELOW 5.0 OHMS? 5-VOLT SUPPLY
5-VOLT SUPPLY CKT. CIRCUIT.*
FIG.3
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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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-76AREPAIRING - SMART START RELAY SHORT CIRCUIT
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
REPLACE THE
START TEST STARTER RELAY WITH
TC-76A. A KNOWN GOOD
RELAY.
FIG.1
FULLY DEPRESS THE
CLUTCH PEDAL AND DOES THE ENGINE YES REPLACE THE
ATTEMPT TO CRANK CRANK? INITIAL STARTER
THE ENGINE RELAY.
NO
KEY OFF.
REMOVE THE STARTER REMOVE THE DIESEL
DISCONNECT THE ECM RELAY.** POWER RELAY.**
HARNESS
CONNECTORS.**
WITH A JUMPER WIRE, KEY ON. USING A REPAIR THE STARTER
CONNECT DIESEL POWER TEST LIGHT, PROBE IS THE TEST LIGHT YES RELAY CONTROL
RELAY CONN. CAVITIES THE STARTER RELAY ON? CIRCUIT FOR A
30 AND 87 (IN PDC). CONTROL CIRCUIT. SHORT TO VOLTAGE.*
FIG.1 FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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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-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-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 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.*
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TEST SC-3BCHECKING SPEED CONTROL OPERATION
Perform TEST SC-3A Before Proceeding
*Perform Verification TEST VER-3A. **Check connectors - Clean / repair as necessary.
START TEST
SC-3B. TURN IGNITION OFF.
DISCONNECT THE KEY ON. USING A
BRAKE LAMP SWITCH VOLTMETER, MEASURE IS THE VOLTAGE NO CONTINUE TEST
HARNESS VOLTAGE AT CAVITY 1. ABOVE 9.0 VOLTS? SC-3B ON THE
CONNECTOR.** NEXT PAGE.
FIG.1
YES
USING A JUMPER WHILE MONITORING DID THE DRB
WIRE, CONNECT THE DRB. DISPLAY CHANGE YES ADJUST OR REPLACE
BRAKE LAMP SWITCH FROM "PRESSED" TO THE BRAKE LAMP
CONNECTOR CAVITY 1 "RELEASED"? SWITCH.*
TO GROUND... FIG.1
NO
USING AN OHMMETER,REPAIR THE OPEN
MEASURE THE IS THE RESISTANCE YES SECONDARY BRAKE
RESISTANCE BETWEEN ABOVE 10.0 OHMS? LAMP SWITCH GROUND
CONNECTOR CAVITY 2CIRCUIT.*
AND GROUND. FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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