2000 CHRYSLER CARAVAN engine

The secret key and challenge are plugged into an algorithm that produces the encrypted response
message. The transponder uses the crypto algorithm to receive, decode and respond to the
message sent by SKIM. After responding to the coded message, the transponder sends a
transponder I.D. message to the SKIM. The SKIM compares the transponder I.D. to the available
valid key codes in SKIM memory (8 key maximum). After validating the key the SKIM sends a
CCD Bus message called a ªSeed Requestº to the body controller then waits for a body controller
response. If the body controller does not respond, the SKIM will send the seed request again.
After three failed attempts the SKIM will stop sending the seed request and store a trouble code.
If the body controller sends a seed response, the SKIM sends a valid/invalid key message to the
body controller. This is an encrypted message that is generated using the following:
VIN þ Vehicle Identification Number
Seed þ This is a random number that is generated by the BCM at each ignition key cycle.
The VIN and seed are plugged into a rolling code algorithm that encrypts the ªvalid/invalid keyº
message. The body controller uses the rolling code algorithm to receive, decode and respond to
the valid/invalid key message sent by SKIM. After sending the valid/invalid key message the SKIM
waits 3.5 seconds for a PCM status message from the body controller. If the BCM does not
respond with a valid key message to the SKIM, a fault is detected and a trouble code stored.
The SKIS incorporates a warning (``ALARM SET'') lamp located in the message center. The lamp
receives switched ignition voltage and is hardwired to the body controller. The lamp is actuated
when the SKIM sends a CCD Bus message to the body controller requesting the lamp on. The
body controller then provides the ground for the lamp. The SKIM will request lamp operation for
the following:
± ± bulb check at ignition on
± to alert the vehicle operator to a SKIS malfunction
For all faults except transponder faults and VIN mismatch, the lamp remains on steady. In the
event of a transponder fault the light flashes at the rate of 1Hz (once per second). If a fault is
present the lamp will remain on or flashing for the complete ignition cycle. If a fault is stored in
SKIM memory which prevents the system from operating properly, the ECM will allow the engine
to start and run (for 2 seconds) up to six times. After the sixth attempt, the ECM disables the
starter relay until the fault is corrected..
3.3 Diagnostic Trouble Codes
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The
diagnostic test procedures contain step-by-step instructions for determining the cause of trouble
codes as well as no trouble code problems. It is not necessary to perform all of the tests in this
book to diagnose an individual code.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins in
the DTC TEST - Checking the System for Diagnostic Trouble Codes. This will direct you to the
specific test(s) that must be performed.
3.3.1 Hard Code
A diagnostic trouble code that comes back within one cycle of the ignition key is a ªhardº code.
This means that the defect is there every time the engine control module/SKIM checks that circuit
or function. Procedures in this manual verify if the trouble code is a hard code at the beginning
of each test. When it is not a hard code, an ªintermittentº test must be performed.
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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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EGR OPEN CIRCUIT
EGR SHORT CIRCUIT
ENGINE SPEED SENSOR DYNAMIC PLAUSIBILITY
ENGINE SPEED SENSOR OVER SPEED RECOGNITION
ENGINE SPEED SENSOR STATIC PLAUSIBILITY
FAN CONTROL OPEN CIRCUIT FAN#1
FAN CONTROL OPEN CIRCUIT FAN #2
FAN CONTROL SHORT CIRCUIT FAN #1
FAN CONTROL SHORT CIRCUIT FAN #2
FUEL QUANTITY ACTUATOR NEG. GOV. DEVIATION COLD
FUEL QUANTITY ACTUATOR NEG. GOV. DEVIATION WARM
FUEL QUANTITY ACTUATOR POS. GOV. DEVIATION COLD
FUEL QUANTITY ACTUATOR POS. GOV. DEVIATION WARM
FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED
FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED
GLOW RELAY #1 CONTROLLER OPEN CIRCUIT
GLOW RELAY #2 CONTROLLER OPEN CIRCUIT
GLOW RELAY #1 CONTROLLER SHORT CIRCUIT
GLOW RELAY #2 CONTROLLER SHORT CIRCUIT
IMMOBILIZER SIGNAL LOST
INVALID SKIM MESSAGE
INDUCTIVE AUX. SPEED SENSOR DYNAMIC PLAUSIBILITY
INDUCTIVE AUX. SPEED SENSOR OVERSPEED RECOGNITION
INDUCTIVE AUX. SPEED SENSOR PLAUSIBILITY
INDUCTIVE AUX. SPEED SENSOR STATIC PLAUSIBILITY
MICROCONTROLLER GATE-ARRAY MONITORING
MICROCONTROLLER GATE-ARRAY WATCHDOG
MICROCONTROLLER PREPARE FUEL QUANTITY STOP
MICROCONTROLLER RECOVERY HAS OCCURRED
MICROCONTROLLER REDUNDANT OVERRUN MONITORING
NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED
NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED
REDUNDANT EMER. STOP PLAUSIBILITY IN AFTER-RUN
REDUNDANT EMER. STOP POWERSTAGE DEFECTIVE
REGULATOR LOWER REGULATOR LIMIT
REGULATOR UPPER LIMIT
SOLENOID VALVE CONTROLLER OPEN CIRCUIT
SOLENOID VALVE CONTROLLER SHORT CIRCUIT
TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED
TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED
TERMINAL #15 PLAUSIBILITY AFTER START-UP
TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION
TIMING GOVERNING POSITIVE GOVERNOR DEVIATION
TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED
TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED
TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED
TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED
TURBOCHARGER BOOST SENSOR PLAUSIBILITY
VEHICLE SPEED SENSOR PEC FREQUENCY TOO HIGH
VEHICLE SPEED SENSOR SIGNAL SRC HIGH EXCEEDED
VEHICLE SPEED SENSOR PLAUSIBILITYG
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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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4.8 Lamps and Indicators
The ªCruiseº lamp is controlled by the Body Control Module. The Diagnostic/Glow Plug lamp is
controlled by the Engine Control Module. The ªAlarm Setº lamp is controlled by the SKIM.
5.0 DISCLAIMERS, SAFETY, WARNINGS
5.1 Disclaimers
All information, illustrations, and specifications contained in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any time
without notice.
5.2 Safety
5.2.1 Technician Safety Information
WARNING!!Engines produce carbon monoxide that is odorless, causes slower reaction time,
and can lead to serious injury. When the engine is operating, keep service areas WELL
VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system.
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the
drive wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
When diagnosing a powertrain system problem, it is important to follow approved procedures
where applicable. These procedures can be found in the service manual. Following these
procedures is very important to the safety of individuals performing diagnostic tests.
5.2.2 Vehicle Preparation for Testing
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
5.2.3 Servicing Sub-Assemblies
Some components of the powertrain system are intended to be serviced in assembly only.
Attempting to remove or repair certain system sub-components may result in personal injury
and/or improper system operation. Only those components with approved repair and installation
procedures in the service manual should be serviced.
5.2.4 DRBIIITSafety Information
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to
serious or possibly fatal injury. Carefully read and understand the cautions and the
specification limits.
²Follow the vehicle manufacturer's service specifications at all times.
²Do not use the DRB if it has been damaged.
²Do not use the test leads if the insulation is damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
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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 DTCCHECKING FOR DIAGNOSTIC TROUBLE CODES
DRBIIITDIAGNOSTIC TROUBLE CODE (DTC) DISPLAYEDDIAGNOSTIC
TESTSCAN
TOOL
Engine Speed Sensor Over Speed Recognition TC-36 P0725
Engine Speed Sensor Static Plausibility TC-38 P0725
Fan Control Open Circuit Fan #1TC-39 P1690
Fan Control Open Circuit Fan #2TC-40 P1690
Fan Control Short Circuit Fan #1TC-41 P1690
Fan Control Short Circuit Fan #2TC-42 P1690
Fuel Quantity Actuator Neg. Gov. Deviation Cold TC-43 P1220
Fuel Quantity Actuator Neg. Gov. Deviation Warm TC-44 P1220
Fuel Quantity Actuator Pos. Gov. Deviation Cold TC-45 P1220
Fuel Quantity Actuator Pos. Gov. Deviation Warm TC-46 P1220
Fuel Temperature Sensor SRC High Exceeded TC-47 P0180
Fuel Temperature Sensor SRC Low Exceeded TC-48 P0180
Glow Relay #1 Controller Open Circuit TC-51 P1635
Glow Relay #2 Controller Open Circuit TC-52 P1635
Glow Relay #1 Controller Short Circuit TC-53 P1635
Glow Relay #2 Controller Short Circuit TC-54 P1635
Inductive Aux. Speed Sensor Dynamic Plausibility TC-56 P1725
Inductive Aux. Speed Sensor Overspeed Recognition TC-57 P1725
Inductive Aux. Speed Sensor Plausibility TC-58 P1725
Inductive Aux. Speed Sensor Static Plausibility TC-59 P1725
Intake Air Temperature Sensor Signal High Exceeded TC-62 P0110
Intake Air Temperature Sensor Signal Low Exceeded TC-63 P0110
Microcontroller Gate-array Monitoring** P1615
Microcontroller Gate-array Watchdog** P1615
Microcontroller Prepare Fuel Quantity Stop ** P1615
Microcontroller Recovery Has Occurred ** P1615
Microcontroller Redundant Overrun Monitoring ** P1615
Needle Movement Sensor High Exceeded TC-72 P1201
Needle Movement Sensor Low Exceeded TC-73 P1201
Redundant Emer. Stop Plausibility in After-run TC-74 P1660
Redundant Emer. Stop Powerstate Defective TC-75 P1660
Regulator Lower Regulator Limit** P1610
Regulator Upper Regulator Limit** P1610
Smart Start Relay Short CircuitTC-76 P1675
Solenoid Valve Controller Open Circuit TC-79 P1630
Solenoid Valve Controller Short Circuit TC-80 P1630
Temperature of Engine Coolant SRC High Exceeded TC-81 P0115
Temperature of Engine Coolant SRC Low Exceeded TC-82 P0115
Terminal #15 Plausibility After Start-up TC-84 P1605
Timing Governing Negative Governor Deviation TC-85 P1230
Timing Governing Positive Governor Deviation TC-86 P1230
UþREF (2.5V)** P1620
Vehicle Speed Sensor Pec Frequency Too High TC-91 P0500
Vehicle Speed Sensor Signal High Exceeded TC-91 P0500
Vehicle Speed Sensor PlausibilityTC-91 P0500
Immobilizer Signal LostTC-94 P1685
Invalid SKIM MessageTC-94 P1685
** These trouble codes indicate an internal ECM fault. Using the DRB, clear ECM trouble code(s).
Perform several engine run cycles turning the ignition off for at least 10 seconds between cycles.
Using the DRB, read ECM trouble codes. If the code is present, replace the Engine Control Module.
NOTE: If trouble code TERMINAL 15 PLAUSIBILITY AFTER START-UP is present with other trouble
codes, perform TC-84 diagnosis first.
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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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