radiator 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
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3.2 Functional Operation
3.2.1 ECM On-Board Diagnostics
The ECM has been programmed to monitor many different circuits of the diesel fuel injection
system. This monitoring is called ``on-board diagnosis''.
Certain criteria must be met for a diagnostic trouble code to be entered into the ECM memory. The
criteria may be a range of: engine rpm, engine temperature, and/or input voltage to the ECM. If
all of the criteria for monitoring a system or circuit are met and a problem is sensed, then a trouble
code will be stored in the ECM.
It is possible that a trouble code for a monitored circuit may not be entered into the ECM memory
even though a malfunction has occurred. This may happen when the monitoring criteria have not
been met.
The ECM compares input signal voltages from each input device with specifications (the
established high and low limits of the range) that are programmed into it for that device. If the input
voltage is not within specifications and other trouble code criteria are met, a trouble code will be
stored in the ECM memory.
3.2.2 ECM Operating Modes
As input signals to the engine control module (ECM) change, the ECM adjusts its response to
output devices. For example, the ECM must calculate a different fuel quantity and fuel timing for
idle than it does for wide open throttle. There are several different modes of operation that
determine how the ECM responds to the various input signals.
Ignition Switch On (Engine Off Mode)
When the ignition switch activates the fuel injection system, the following actions occur:
1. The ECM determines atmospheric air pressure from the atmospheric pressure sensor
located in the ECM.
2. The ECM energizes the fuel quantity actuator and the fuel shudown solenoid if no faults
are present.
If the engine is not started within 5 seconds of ignition on, the ECM deactivates the fuel quantity
actuator and the fuel shutdown solenoid to prevent overheating.
Engine Start-Up Mode-The ECM uses the engine temperature sensor, fuel temperature sensor,
atmospheric pressure sensor, boost pressure sensor and the engine speed sensor to determine
fuel delivery during this mode.
Normal Driving Modes- Engine idle, warm-up, acceleration, deceleration and wide open throttle
modes are all controlled based on the sensor inputs to the ECM and are modified based on
engine temperature, boost pressure and engine speed.
Overheat Protection Mode- If engine temperature becomes too hot, the ECM activates high
speed radiator fan operation and limits fuel quantity for engine protection.
Limp-In Modes- The ECM operates in limp-in mode when certain system faults are detected.
The ECM operates in one of the following modes based on the severity of the fault:
1. 10% torque reduction.
2. 50% torque reduction.
3. Engine speed limited to 1100 rpm.
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TEST TC-39AREPAIRING - FAN CONTROL OPEN CIRCUIT FAN 1
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON. IS THE RADIATOR
START TEST WITH THE DRB, FAN #2 RELAY NO CONTINUE TEST
TC-39A. ACTUATE THE LOW CLICKING ON AND TC-39A ON THE
SPEED RADIATOR OFF? NEXT PAGE.
FAN.
YES
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
WIGGLE THE WIRING REPAIR AS NECESSARY
HARNESS FROM THE NOTE: THE DRB MUST DID THE WIGGLING YES WHERE WIGGLING
RELAY TO THE STILL BE ACTUATING INTERRUPT FAN CAUSED FAN RELAY
ENGINE CONTROL THE FAN RELAY. RELAY CLICKING? CLICKING TO BE
MODULE.INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-39ACONTINUED - REPAIRING - FAN CONTROL OPEN CIRCUIT FAN 1
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-39A TURN IGNITION OFF.
CONTINUED FROM
THE PREVIOUS REMOVE RADIATOR
PAGE. FAN RELAY #2.**
TURN IGNITION ON. MEASURE THE DIESEL
POWER RELAY OUTPUT IS THE VOLTAGE NO REPAIR THE OPEN
USE A VOLTMETER IN CIRCUIT. ABOVE 10.0 VOLTS? DIESEL POWER RELAY
THE FOLLOWINGOUTPUT CIRCUIT.*
STEP. FIG.1
YES
TURN IGNITION OFF. MEASURE THE
RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE RADIATOR
USE AN OHMMETER IN TERMINALS 85 AND 86 BELOW 100.0 OHMS? FAN RELAY #2.*
THE FOLLOWING OF THE #2 RELAY.
STEPS. FIG.2
YES
KEY OFF. MEASURE THE REPAIR THE LOW
DISCONNECT THE ECM RESISTANCE BETWEEN IS THE RESISTANCE YES SPEED FAN CONTROL
HARNESS GROUND AND ECM BELOW 5.0 OHMS? CKT FOR A SHORT TO
CONNECTORS.** HARNESS CONNECTOR GROUND.*
CAVITY 17. FIG.3
NO
MEASURE THE FROM THE RELAY TO
RESISTANCE OF THE ECM HARNESS IS THE RESISTANCE NO REPAIR OPEN LOW
LOW SPEED FAN CONNECTOR CAVITY 17. BELOW 5.0 OHMS? SPEED FAN CONTROL
CONTROL CIRCUIT... CIRCUIT.*
FIG.1 AND 3
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-40AREPAIRING - FAN CONTROL OPEN CIRCUIT FAN 2
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON. ARE THE RADIATOR
START TEST WITH THE DRB, FAN RELAYS #1 AND NO CONTINUE TEST
TC-40A. ACTUATE THE HIGH #3 CLICKING ON AND TC-40A ON THE
SPEED RADIATOR OFF? NEXT PAGE.
FAN.
YES
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
WIGGLE THE WIRING REPAIR AS
HARNESS FROM THE NOTE: THE DRB MUST DID THE WIGGLING YES NECESSARY WHERE
RELAYS TO THE STILL BE ACTUATING INTERRUPT FAN WIGGLING CAUSED
ENGINE CONTROL THE FAN RELAY. RELAY CLICKING? RELAY CLICKING TO
MODULE.BE INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-40ACONTINUED - REPAIRING - FAN CONTROL OPEN CIRCUIT FAN 2
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-40A TURN IGNITION OFF.
CONTINUED FROM
THE PREVIOUS REMOVE RADIATOR FAN
PAGE. RELAYS #1 AND #3.**
TURN IGNITION ON. MEASURE THE DIESEL IS THE VOLTAGE
POWER RELAY OUTPUT ABOVE 10.0 VOLTS NO REPAIR THE OPEN
USE A VOLTMETER IN CIRCUIT AT EACH FOR EACH DIESEL POWER RELAY
THE FOLLOWING RELAY CONNECTOR. MEASUREMENT? OUTPUT CIRCUIT.*
STEP. FIG.1 AND 2
YES
TURN IGNITION OFF. MEASURE THE IS THE RESISTANCE REPLACE THE
RESISTANCE BETWEEN BELOW 100.0 OHMS NO RADIATOR FAN RELAY
USE AN OHMMETER IN TERMINALS 85 AND FOR EACH THAT MEASURED
THE FOLLOWING 86 OF THE #1 AND MEASUREMENT? ABOVE 100.0 OHMS.*
STEPS. #3 RELAYS. FIG.3
YES
KEY OFF. MEASURE THE REPAIR THE HIGH
DISCONNECT THE ECM RESISTANCE BETWEEN IS THE RESISTANCE YES SPEED FAN CONTROL
HARNESS GROUND AND ECM BELOW 5.0 OHMS? CKT FOR A SHORT TO
CONNECTORS.** HARNESS CONNECTOR GROUND.*
CAVITY 41. FIG.4
NO
MEASURE THE FROM EACH RELAY TO
RESISTANCE OF THE ECM HARNESS IS THE RESISTANCE NO REPAIR OPEN HIGH
HIGH SPEED FAN CONNECTOR CAVITY 41. BELOW 5.0 OHMS FOR SPEED FAN CONTROL
CONTROL CIRCUIT... EACH MEASUREMENT? CIRCUIT.*
FIG.1, 2 AND 4
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-41AREPAIRING - FAN CONTROL SHORT CIRCUIT FAN 1
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON. IS THE RADIATOR
START TEST WITH THE DRB, FAN #2 RELAY NO CONTINUE TEST
TC-41A. ACTUATE THE LOW CLICKING ON AND TC-41A ON THE
SPEED RADIATOR OFF? NEXT PAGE.
FAN.
YES
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
WIGGLE THE WIRING REPAIR AS NECESSARY
HARNESS FROM THE NOTE: THE DRB MUST DID THE WIGGLING YES WHERE WIGGLING
RELAY TO THE STILL BE ACTUATING INTERRUPT FAN CAUSED FAN RELAY
ENGINE CONTROL THE FAN RELAY. RELAY CLICKING. CLICKING TO BE
MODULE.INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2 YES
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-41ACONTINUED - REPAIRING - FAN CONTROL SHORT CIRCUIT FAN 1
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-41A
CONTINUED FROM REMOVE RADIATOR
THE PREVIOUS FAN RELAY #2.**
PAGE.
USING AN OHMETER, 85 AND 86 IS THE RESISTANCE
MEASURE RESISTANCE 85 AND 30 BELOW 30.0 OHMS YES REPLACE RADIATOR
BETWEEN RADIATOR 85 AND 87. FOR ANY OF THE FAN RELAY #2.*
FAN #2 RELAY MEASUREMENTS?
TERMINALS... FIG.1
NO
TURN IGNITION OFF.
DISCONNECT THE ECM REMOVE DIESEL
HARNESS POWER RELAY.**
CONNECTORS.**
WITH A JUMPER WIRE,
CONNECT DIESEL POWER
RELAY CONN. CAVITIES TURN IGNITION ON.
30 AND 87 (IN PDC).
FIG.2
MEASURE THE RELAY REPAIR RADIATOR
USE A VOLTMETER IN CONTROL CIRCUIT AT IS THE VOLTAGE YES FAN RELAY #2
THE FOLLOWING ECM HARNESS ABOVE 1.0 VOLT? CONTROL CIRCUIT
STEP. CONNECTOR CAVITY 17. FOR SHORT TO
FIG. 3 VOLTAGE.*
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-42AREPAIRING - FAN CONTROL SHORT CIRCUIT FAN 2
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
KEY ON. ARE THE RADIATOR
START TEST WITH THE DRB, FAN RELAYS #1 AND NO CONTINUE TEST
TC-42A. ACTUATE THE HIGH #3 CLICKING ON AND TC-42A ON THE
SPEED RADIATOR OFF? NEXT PAGE.
FAN.
YES
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
WIGGLE THE WIRING REPAIR AS
HARNESS FROM THE NOTE: THE DRB MUST DID THE WIGGLING YES NECESSARY WHERE
RELAYS TO THE STILL BE ACTUATING INTERRUPT FAN WIGGLING CAUSED
ENGINE CONTROL THE FAN RELAY. RELAY CLICKING? RELAY CLICKING TO
MODULE.BE INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETED.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-42ACONTINUED - REPAIRING - FAN CONTROL SHORT CIRCUIT FAN 2
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-42A
CONTINUED FROM REMOVE RADIATOR
THE PREVIOUS FAN RELAYS
PAGE. #1 AND #3.**
USING AN OHMETER, 85 AND 86, 85 AND IS THE RESISTANCE
MEASURE RESISTANCE 30, 85 AND 87. BELOW 30.0 OHMS YES REPLACE SHORTED
BETWEEN RADIATOR REPEAT MEASUREMENTS FOR ANY OF THE RADIATOR FAN
FAN #1 RELAY ON RADIATOR FAN MEASUREMENTS? RELAY.*
TERMINALS... RELAY #3. FIG.1
NO
TURN IGNITION OFF.
DISCONNECT THE ECM REMOVE THE DIESEL
HARNESS POWER RELAY.**
CONNECTORS.**
WITH A JUMPER WIRE,
CONNECT DIESEL POWER
RELAY CONN. CAVITIES TURN IGNITION ON.
30 AND 87 (IN PDC).
FIG.2
MEASURE THE RELAY REPAIR RADIATOR
USE A VOLTMETER IN CONTROL CIRCUIT AT IS THE VOLTAGE YES FAN RELAY #1 AND
THE FOLLOWING ECM HARNESS ABOVE 1.0 VOLT? #3 CONTROL CIRCUIT
STEP. CONNECTOR CAVITY 41. FOR A SHORT TO
FIG.3 VOLTAGE.*
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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