2000 CHRYSLER CARAVAN clutch

TABLE OF CONTENTS - Continued
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES...........................19
7.1GENERAL TROUBLESHOOTING....................................19
TROUBLE CODE TESTS
TEST DTCCHECKING FOR DIAGNOSTIC TROUBLE CODES.............20
TC-1AREPAIRING - A/C CONTROL SHORT CIRCUIT.................22
TC-2AREPAIRING - A/C CONTROL OPEN CIRCUIT..................28
TC-3AREPAIRING - A/C SYSTEM PRESSURE SIGNAL HIGH
EXCEEDED..............................................34
TC-4AREPAIRING - A/C SYSTEM PRESSURE SIGNAL LOW
EXCEEDED..............................................38
TC-5AREPAIRING - A/C SYSTEM PRESSURE SUPPLY HIGH
EXCEEDED..............................................42
TC-6AREPAIRING - A/C SYSTEM PRESSURE SUPPLY LOW
EXCEEDED..............................................46
TC-7AREPAIRING - ACCELERATOR PEDAL SENSOR TROUBLE
CODES.................................................50
TC-14AREPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED.......60
TC-15AREPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH
EXCEEDED..............................................62
TC-16AREPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW
EXCEEDED..............................................70
TC-17AREPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY HIGH
EXCEEDED..............................................74
TC-18AREPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY LOW
EXCEEDED..............................................78
TC-19AREPAIRING - TURBOCHARGER BOOST SENSOR PLAUSIBILITY.82
TC-20AREPAIRING - BRAKE SWITCH PLAUSIBILITY WITH REDUNDANT
CONTACT...............................................86
TC-21AREPAIRING - CLUTCH SIGNAL PLAUSIBILITY.................94
TC-22AREPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH
EXCEEDED..............................................98
TC-23AREPAIRING - CONTROL SLEEVE SENSOR START END POSITION
NOT ATTAINED..........................................102
TC-24AREPAIRING - CONTROL SLEEVE SENSOR STOP END POSITION
NOT ATTAINED..........................................104
TC-25AREPAIRING - CRUISE STATUS INDICATOR LAMP SHORT
CIRCUIT................................................106
TC-26AREPAIRING - DIAGNOSTIC LAMP OPEN CIRCUIT............110
TC-27AREPAIRING - DIAGNOSTIC LAMP SHORT CIRCUIT...........114
TC-30AREPAIRING - DIESEL POWER RELAY SHUTS OFF TOO EARLY .118
TC-31AREPAIRING - DIESEL POWER RELAY SHUTS OFF TOO LATE . .122
TC-33AREPAIRING - EGR OPEN CIRCUIT.........................126
TC-34AREPAIRING - EGR SHORT CIRCUIT........................130
TC-35AREPAIRING - ENGINE SPEED SENSOR DYNAMIC
PLAUSIBILITY...........................................134
TC-36AREPAIRING - ENGINE SPEED SENSOR OVERSPEED
RECOGNITION..........................................138
TC-38AREPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY .140
TC-39AREPAIRING - FAN CONTROL OPEN CIRCUIT FAN 1..........144
TC-40AREPAIRING - FAN CONTROL OPEN CIRCUIT FAN 2..........148
TC-41AREPAIRING - FAN CONTROL SHORT CIRCUIT FAN 1.........152
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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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4.0 SYSTEM COMPONENT LOCATIONS
4.1 Engine Control Module
2.5L
CAV CKT/COLOR FUNCTION
1 Z12 BK/TN Ground
2 A142 DG/OR Diesel Power Relay Output
3 K90 TN Starter Relay Control
5 C13 DB/OR A/C Compressor Clutch Control
6 K159 VT/RD Engine Speed Sensor Signal
Output
8 C103 DG/LB A/C Switch Signal
9 K29 WT/PK Secondary Brake Switch Signal
11 K6 VT/WT 5-Volt Supply
12 K151 WT Low Idle Position Switch Sense
13 K21 BK/RD Intake Air Temperature Sensor
Signal
17 C24 DB/PK Low Speed Fan Control
20 L50 WT/TN Primary Brake Switch Signal
23 K167 BR/YL Accelerator Pedal Position
Sensor Ground
24 K22 OR/DB Accelerator Pedal Position
Sensor Signal
27 Z12 BK/TN Ground
28 A142 DG/OR Diesel Power Relay Output
29 K35 GY/YL EGR Solenoid Control
30 V38 LB/RD Speed Control Lamp Control
33 K51 DB/YL Diesel Power Relay Control
34 G85 OR/BK Diagnostic/Glow Plug Lamp
Control
38 G56 OR/BK Immobilizer Signal
39 K9 LB 5-Volt Supply
40 K1 DG/RD Boost Pressure Sensor Signal
41 C137 YL High Speed Fan ControlCAV CKT/COLOR FUNCTION
42 K152 WT/DG Glow Plug Relay #1 Control
43 K252 LG/OR Glow Plug Relay #2 Control
45 D21 PK ISO K-line
46 K119 LG/BK Clutch Pedal Switch Signal
47 F87 WT/BK Ignition Switch Supply
50 K7 OR 5-Volt Supply
51 G7 WT/OR Vehicle Speed Sensor Signal
52 C18 DB A/C Pressure Sensor Signal
53 K156 GY Fuel Temperature Sensor Signal
54 K2 TN/BK Engine Coolant Temperature
Sensor Signal
55 K68 LG/YL Needle Movement Sensor
Ground
56 K134 LB/BK Control Sleeve Position Sensor
Signal
57 K57 LG/OR Middle Tap
58 K135 WT/BK Measure Coil
59 K140 TN/WT Fuel Quantity Actuator Control
60 V37 RD/LG Speed Control Switch Signal
61 K4 BK/LB Sensor Ground
62 K67 BR/BL Needle Movement Sensor
Signal
66 K140 TN/WT Fuel Quantity Actuator Control
67 K24 GY/BK Engine Speed Sensor Signal
69 K3 BK/VT Engine Speed Sensor Ground
77 K153 OR/DG Fuel Shutdown Solenoid Control
79 K126 LG Fuel Timing Solenoid Control
80 K140 TN/WT Fuel Quantity Actuator Control
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TEST DTCCHECKING FOR DIAGNOSTIC TROUBLE CODES
NOTE: The battery must be fully charged for any test in this manual.
1. Attempt to start the engine. Crank for up to 10 seconds if necessary.
2. Connect the DRB to the data link connector. Write down the trouble codes that are displayed.
3. If the DRB displays ``No Response'', go toTEST NS-2A.
4. If the DRB screen is blank or has a DRB error message, go toGeneral Information Section
3.5in this manual.
5. Iftrouble code messagesare displayed, refer to the trouble code list below and on the
following page for the appropriate test.
6. If there are no ECM trouble codes displayed, refer to one of the following:
For Immobilizer problems..................................................SK-1A
For Driveability problems.................................................NTC-1A
For No Start problems....................................................NS-1A
For Speed Control problems...............................................SC-1A
NOTE:For all component locations see General Information Section 4.0 in this manual.
DRB DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYEDDIAGNOSTIC
TESTSCAN
TOOL
AC Control Short CircuitTC-1 P1655
A/C Control Open CircuitTC-2 P1655
A/C System Pressure Signal High Exceeded TC-3 P1695
A/C System Pressure Signal Low Exceeded TC-4 P1695
A/C System Pressure Supply High Exceeded TC-5 P1695
A/C System Pressure Supply Low Exceeded TC-6 P1695
Accelerator Pedal Sensor High Exceeded TC-7 P1515
Accelerator Pedal Sensor PlausibilityTC-7 P1515
Accelerator Pedal Sensor Pwg Plaus With Low Idle Switch TC-7 P1515
Accelerator Pedal Sensor Pwg Plaus With Potentiometer TC-7 P1515
Atmospheric Pressure Sensor SRC High Exceeded ** P1105
Atmospheric Pressure Sensor SRC Low Exceeded ** P1105
Battery Voltage SRC High Exceeded TC-14 P1600
Turbocharger Boost Sensor Signal High Exceeded TC-15 P0235
Turbocharger Boost Sensor Signal Low Exceeded TC-16 P0235
Turbocharger Boost Sensor Supply High Exceeded TC-17 P0235
Turbocharger Boost Sensor Supply Low Exceeded TC-18 P0235
Turbocharger Boost Sensor Plausibility TC-19 P0235
Brake Signal Plaus With Redundant Contact TC-20 P1703
Clutch Signal PlausibilityTC-21 P1740
Control Sleeve Sensor Signal High Exceeded TC-22 P1225
Control Sleeve Sensor Start End Pos. Not Attained TC-23 P1225
Control Sleeve Sensor Stop End Pos. Not Attained TC-24 P1225
Cruise Status Indicator Lamp Short Circuit TC-25 P1665
Diagnostic Lamp Open CircuitTC-26 P1650
Diagnostic Lamp Short CircuitTC-27 P1650
Diesel Power Relay Shuts Off Too Early TC-30 P1625
Diesel Power Relay Shuts Off Too Late TC-31 P1625
EEPROM Plausibility Checksum Error For Adj. ** P1680
EEPROM Plausibility Checksum Error in CC212 ** P1680
EEPROM Plausibility Communication with EEPROM ** P1680
EEPROM Plausibility Func. Switch Wrong or Missing ** P1680
EEPROM Plausibility Ver. Number Not Corresponding ** P1680
EGR Open CircuitTC-33 P0400
EGR Short CircuitTC-34 P0400
Engine Speed Sensor Dynamic Plausibility TC-35 P0725
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TEST TC-1ACONTINUED - REPAIRING - A/C CONTROL SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-1A TURN IGNITION ON.
CONTINUED FROM IS THE A/C CLUTCH NO CONTINUE TEST
THE PREVIOUS WITH THE DRB, RELAY CLICKING? TC-1A ON THE
PAGE. ACTUATE THE A/C NEXT PAGE.
CLUTCH RELAY.
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 NOTE: THE DRB MUST REPAIR AS
HARNESS FROM THE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
RELAY TO THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
ENGINE CONTROL 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-1ACONTINUED - REPAIRING - A/C CONTROL SHORT CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-1A
CONTINUED FROM TURN IGNITION OFF.
THE PREVIOUS REMOVE THE A/C
PAGE. CLUTCH RELAY.**
USING AN OHMMETER, 85 AND 86 IS THE RESISTANCE
MEASURE RESISTANCE 85 AND 87 BELOW 30.0 OHMS YES REPLACE THE A/C
BETWEEN A/C CLUTCH 85 AND 30 FOR ANY OF THE CLUTCH RELAY.*
RELAY TERMINALS... 85 AND 87A MEASUREMENTS?
FIG.2
NO
DISCONNECT THE ECM REMOVE THE DIESEL
HARNESS POWER RELAY.**
CONNECTORS.**
WITH A JUMPER WIRE, TURN IGNITION ON.
CONNECT DIESEL POWER
RELAY CONN. CAVITIES USE A VOLTMETER IN
30 AND 87 (IN PDC). THE FOLLOWING
FIG.3 STEP.
MEASURE THE RELAYREPAIR A/C CLUTCH
CONTROL CIRCUIT AT IS THE VOLTAGE YES RELAY CONTROL
RELAY CONNECTOR ABOVE 1.0 VOLT? CIRCUIT FOR SHORT
(IN PDC).TO VOLTAGE.*
FIG.1
NO
REPLACE THE ENGINE
CONTROL MODULE.*
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TEST TC-2ACONTINUED - REPAIRING - A/C CONTROL OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-2A TURN IGNITION ON.
CONTINUED FROM IS THE A/C CLUTCH NO CONTINUE TEST
THE PREVIOUS WITH THE DRB, RELAY CLICKING? TC-2A ON THE
PAGE. ACTUATE THE A/C NEXT PAGE.
CLUTCH RELAY.
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 NOTE: THE DRB MUST REPAIR AS
HARNESS FROM THE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
RELAY TO THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
ENGINE CONTROL 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-2ACONTINUED - REPAIRING - A/C CONTROL OPEN CIRCUIT
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TEST TC-2A
CONTINUED FROM KEY OFF.
THE PREVIOUS REMOVE THE A/C
PAGE. CLUTCH RELAY.**
USING A VOLTMETER,
MEASURE THE DIESEL IS THE VOLTAGE NO REPAIR THE OPEN
TURN IGNITION ON. POWER RELAY OUTPUT ABOVE 10.0 VOLTS? DIESEL POWER RELAY
CIRCUIT. OUTPUT CIRCUIT.*
FIG.1
YES
KEY OFF. MEASURE THE
RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE A/C
USE AN OHMMETER IN A/C CLUTCH RELAY BELOW 100.0 OHMS? CLUTCH RELAY.*
THE FOLLOWING TERMINALS 85 AND 86.
STEPS. FIG.2
YES
MEASURE THE REPAIR THE A/C
DISCONNECT THE ECM RESISTANCE BETWEEN IS THE RESISTANCE YES CLUTCH RELAY
HARNESS GND AND THE A/C BELOW 5.0 OHMS? CONTROL CKT FOR A
CONNECTORS.** CLUTCH RELAY CONTROL SHORT TO GROUND.*
CKT (IN PDC). FIG.1
NO
MEASURE THE FROM THE RELAY TO
RESISTANCE OF THE THE ECM. IS THE RESISTANCE NO REPAIR OPEN A/C
A/C CLUTCH RELAY BELOW 5.0 OHMS? CLUTCH RELAY
CONTROL CIRCUIT... CONTROL CKT.*
FIG.3
YES
REPLACE THE ENGINE
CONTROL MODULE.*
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