reset CHRYSLER CARAVAN 2000 Service Manual

TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1SYSTEM COVERAGE..............................................1
1.2SIX-STEP TROUBLESHOOTING PROCEDURE.........................1
2.0 IDENTIFICATION OF SYSTEM.............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION......................1
3.1GENERAL DESCRIPTION...........................................1
3.2FUNCTIONAL OPERATION..........................................2
3.2.1ECM On-Board Diagnostics....................................2
3.2.2ECM Operating Modes........................................2
3.2.3Monitored Circuits............................................3
3.2.4SKIS On-Board Diagnostics....................................3
3.2.5SKIS Overview...............................................3
3.2.6SKIS Operation..............................................3
3.3DIAGNOSTIC TROUBLE CODES.....................................4
3.3.1Hard Code..................................................4
3.3.2Intermittent Code.............................................5
3.3.3Reset Counter...............................................5
3.3.4ECM Diagnostic Trouble Codes.................................5
3.3.5SKIM Diagnostic Trouble Codes.................................7
3.3.6Handling No Trouble Code Problems.............................7
3.4USING THE DRB..................................................7
3.5DRB ERROR MESSAGES AND BLANK SCREEN........................7
3.5.1DRB Does Not Power Up......................................8
3.5.2Display is Not Visible..........................................8
4.0 SYSTEM COMPONENT LOCATIONS........................................9
4.1ENGINE CONTROL MODULE........................................9
4.2CONTROLS AND SOLENOIDS......................................10
4.3DATA LINK CONNECTOR..........................................10
4.4SENSORS.......................................................11
4.6RELAYS........................................................13
4.7SWITCHES......................................................15
4.8LAMPS AND INDICATORS.........................................17
5.0 DISCLAIMERS, SAFETY, WARNINGS......................................17
5.1DISCLAIMERS....................................................17
5.2SAFETY.........................................................17
5.2.1Technician Safety Information..................................17
5.2.2Vehicle Preparation for Testing.................................17
5.2.3Servicing Sub-Assemblies.....................................17
5.2.4DRBIIITSafety Information....................................17
5.3WARNINGS......................................................18
5.3.1Vehicle Damage Warnings....................................18
5.3.2Road Testing a Complaint Vehicle..............................18
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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
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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.
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TEST TC-33ACONTINUED - REPAIRING - EGR OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-33A TURN IGNITION OFF.
CONTINUED FROM DISCONNECT THE EGR
THE PREVIOUS SOLENOID HARNESS
PAGE. CONNECTOR.**
KEY ON. USING A
VOLTMETER, MEASURE IS THE VOLTAGE YES REPAIR THE OPEN
THE DIESEL POWER BELOW 10.0 VOLTS? DIESEL POWER RELAY
RELAY OUTPUT CKT. OUTPUT CKT.*
FIG.1
NO
TURN IGNITION OFF. USING AN OHMMETER, REPAIR THE SHORT
DISCONNECT THE ECM MEASURE THE EGR IS THE RESISTANCE YES TO GROUND OF THE
HARNESS SOLENOID CONTROL BELOW 5.0 OHMS? EGR SOLENOID
CONNECTORS.** CIRCUIT TO GROUND. CONTROL CKT.*
FIG.1
NO
USING AN OHMMETER,
MEASURE THE EGR IS THE RESISTANCE YES REPAIR THE OPEN
SOLENOID CONTROL ABOVE 5.0 OHMS? EGR SOLENOID
CIRCUIT. CONTROL CKT.*
FIG.2
NO
RECONNECT THE ECM
REPLACE THE EGR AND EGR SOLENOID DOES THE EGR CODE YES REPLACE THE ENGINE
SOLENOID. CONNECTORS. KEY RESET? CONTROL MODULE.*
ON. USING THE DRB,
CHECK FOR CODES.
NO
TEST COMPLETE.*
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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.*
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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.*
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TEST TC-56ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR DYNAMIC
PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-56A DISCONNECT THE
CONTINUED FROM NEEDLE MOVEMENT
PREVIOUS PAGE. SENSOR HARNESS
CONNECTOR.**
INSPECT THE NEEDLE THE SENSOR HARNESS IS THERE ANY
MOVEMENT SENSOR AND ENGINE HARNESS. DAMAGE OR YES REPAIR AS
CONNECTOR CORROSION AT NECESSARY.*
TERMINALS AT EITHER HARNESS
BOTH.... FIG.1 AND 2. CONNECTOR?
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REPAIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD INDUCE CARRYING WIRES OR MIS-ROUTED?
INTERFERENCE. THE ALTERNATOR.
NO
DISCONNECT THE ECM THE NEEDLE REPAIR THE OPEN IN
HARNESS MOVEMENT SENSOR IS THE RESISTANCE YES THE NEEDLE
CONNECTORS.** USING SIGNAL CIRCUIT. ABOVE 5.0 OHMS? MOVEMENT SENSOR
AN OHMMETER, MEASURESIGNAL CIRCUIT.*
THE RESISTANCE OF... FIG.3
NO
KEY OFF. REPLACE THE START AND OPERATE
NEEDLE MOVEMENT THE ENGINE FROM DOES THIS CODE YES REPLACE THE ENGINE
SENSOR. RECONNECT IDLE TO 3500 RPM RESET? CONTROL MODULE.*
ALL CONNECTORS. KEY WHILE MONITORING
ON. ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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TEST TC-57ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR OVERSPEED
RECOGNITION
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-57A DISCONNECT THE
CONTINUED FROM NEEDLE MOVEMENT
PREVIOUS PAGE. SENSOR HARNESS
CONNECTOR.**
INSPECT THE NEEDLE THE SENSOR HARNESS IS THERE ANY
MOVEMENT SENSOR AND ENGINE DAMAGE OR YES REPAIR AS
CONNECTOR HARNESS. CORROSION AT NECESSARY.*
TERMINALS AT EITHER HARNESS
BOTH.... FIG. 1 AND 2 CONNECTOR?
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REPAIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD INDUCE CARRYING WIRES OR MIS-ROUTED?
INTERFERENCE. THE ALTERNATOR.
NO
DISCONNECT THE ECM THE NEEDLE REPAIR THE OPEN IN
HARNESS MOVEMENT SENSOR IS THE RESISTANCE YES THE NEEDLE
CONNECTORS.** USING SIGNAL CIRCUIT. ABOVE 5.0 OHMS? MOVEMENT SENSOR
AN OHMMETER MEASURESIGNAL CIRCUIT.*
THE RESISTANCE OF... FIG.3
NO
REPLACE THE NEEDLE START AND OPERATE
MOVEMENT SENSOR. THE ENGINE FROM DOES THIS CODE YES REPLACE THE ENGINE
RECONNECT ALL IDLE TO 3500 RPM RESET? CONTROL MODULE.*
CONNECTORS. KEY WHILE MONITORING
ON. ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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TEST TC-58ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION OFF.
TEST TC-58A DISCONNECT THE
CONTINUED FROM NEEDLE MOVEMENT
PREVIOUS PAGE. SENSOR HARNESS
CONNECTOR.**
INSPECT THE NEEDLE THE SENSOR HARNESS IS THERE ANY
MOVEMENT SENSOR AND ENGINE DAMAGE OR YES REPAIR AS
CONNECTOR HARNESS. CORROSION AT NECESSARY.*
TERMINALS AT EITHER HARNESS
BOTH.... FIG. 1 AND 2 CONNECTOR?
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REPAIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD INDUCE CARRYING WIRES OR MIS-ROUTED?
INTERFERENCE. THE ALTERNATOR.
NO
DISCONNECT THE ECM THE NEEDLE REPAIR THE OPEN IN
HARNESS MOVEMENT SENSOR IS THE RESISTANCE YES THE NEEDLE
CONNECTORS.** USING SIGNAL CIRCUIT. ABOVE 5.0 OHMS? MOVEMENT SENSOR
AN OHMMETER, MEASURESIGNAL CIRCUIT.*
THE RESISTANCE OF... FIG.3
NO
REPLACE THE NEEDLE START AND OPERATE
MOVEMENT SENSOR. THE ENGINE FROM DOES THIS CODE YES REPLACE THE ENGINE
RECONNECT ALL IDLE TO 3500 RPM RESET? CONTROL MODULE.*
CONNECTORS. KEY ON WHILE MONITORING
ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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TEST TC-59ACONTINUED - REPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR STATIC
PLAUSIBILITY
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-59A TURN IGNITION OFF.
CONTINUED FROM DISCONNECT THE
THE PREVIOUS NEEDLE MOVEMENT
PAGE. SENSOR HARNESS
CONNECTOR.*
INSPECT THE NEDLE THE SENSOR HARNESS
MOVEMENT SENSOR AND THE ENGINE IS THERE DAMAGE OR YES REPAIR AS
CONNECTOR AT HARNESS. CORROSION AT NECESSARY.*
BOTH... EITHER HARNESS?
FIG.1 AND 2.
NO
CHECK THE WIRING THIS INTERFERENCE
HARNESS FOR COULD BE CAUSED BY IS THE WIRING YES REAPIR AS
MIS-ROUTING THAT LARGE CURRENT HARNESS NECESSARY.*
COULD CAUSE CARRYING WIRES OR MIS-ROUTED?
INTERFERNCE. THE ALTERNATOR.
NO
USING AN OHMMETER, REPAIR THE OPEN IN
DISCONNECT THE ECM MEASURE THE NEEDLE IS THE RESISTANCE YES THE NEEDLE
HARNESS MOVEMENT SENSOR ABOVE 5.0 OHMS? MOVEMENT SENSOR
CONNECTORS.** SIGNAL CIRCUIT. SIGNAL CIRCUIT.*
FIG.3
NO
REPLACE THE NEEDLE START AND OPERATE
MOVEMENT SENSOR. THE ENGINE FROM DOES THE CODE YES REPLACE THE ENGINE
RECONNECT ALL IDLE TO 3500 RPM RESET? CONTROL MODULE.*
CONNECTORS. KEY WHILE MONITORING
ON. ERASE CODES. THE DRB.
NO
TEST COMPLETE.*
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