2000 CHRYSLER CARAVAN battery

TEST NS-SELNO START SELECTION MENU
NOTE:The battery must be fully charged before performing any test in this manual.
NOTE:If the engine will not crank or cranks but will not run, be sure to check the Sentry Key
Immobilizer Module (SKIM) for proper communication and trouble codes.
NOTE:With the DRB, attempt to read ECM trouble codes. If the DRB is unable to communicate with
the ECM, perform test NS-2A. If there are any trouble codes present they must be repaired before
continuing with the No Start Symptom diagnostics.
Below you will find a recommended procedure to correct a No Start Problem by symptom. They
should be performed in the order that they are listed.
Repairing a No Crank Condition..............................................NS-1A
Repairing a No Response Condition...........................................NS-2A
Repairing a No Start Condition................................................NS-3A
Repairing a Start and Stall Condition...........................................NS-4A
Checking the Engine Mechanical Systems......................................NS-5A
NOTE:A failed engine coolant temperature (ECT) sensor can cause a cranks but will not run or an
extended cranking before starting condition. This occurs when the ECT sensor calibration fails
(sensor indicates engine temp is warmer than actual engine temp) and the ECM cannot command
proper fuel quantity to the injection pump.
NOTE:For all component locations seeGeneral Information Section 4.0 in this manual.
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TEST NS-1AREPAIRING A NO CRANK CONDITION
Perform TEST NS-SEL Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
NOTE: BATTERY MUST
START TEST BE FULLY CHARGED
NS-1A. BEFORE DIAGNOSING
A NO-START
CONDITION.
NOTE: BEFORE VEHICLE THEFT DIAGNOSE
CONTINUING, BE (SKIM) SYSTEM FOR ARE ANY CODES YES TROUBLE CODE
SURE TO CHECK DIAGNOSTIC TROUBLE PRESENT? BEFORE
ENGINE SYSTEM CODES. CONTINUING.]
AND...
NO
INSPECT BATTERY
CABLES FOR IS THERE EVIDENCE YES REPAIR AS
TURN IGNITION OFF. CORROSION, OF PROBLEMS? NECESSARY.*
LOOSENESS OR OTHER
PROBLEMS.
NO
TURN IGNITION OFF. KEY ON. WITH A REPAIR THE STARTER
VOLTMETER, MEASURE IS THE VOLTAGE YES RELAY CONTROL
DISCONNECT THE ECM THE STARTER RELAY ABOVE 1.0 VOLT? CIRCUIT FOR A
HARNESS CONTROL CKT. SHORT TO VOLTAGE.*
CONNECTORS.** FIG.1
NO
KEY OFF. USING A FULLY DEPRESS THE
JUMPER WIRE CONNECT CLUTCH PEDAL. DID THE ENGINE YES REPLACE THE ENGINE
THE STARTER RELAY CRANK? CONTROL MODULE.*
CONTROL CKT TO ATTEMPT TO CRANK
GROUND. FIG.1 THE ENGINE.
NO
WITH A VOLTMETER,
DISCONNECT THE MEASURE THE FUSED IS THE VOLTAGE NO REPAIR OPEN FUSED
STARTER RELAY FROM B(+) CIRCUIT. ABOVE 11.6 VOLTS? BATTERY CIRCUIT.*
THE PDC.**
FIG.1
YES
WARNING: THE TRANS WARNING: THE ENGINE BRIEFLY CONNECT A
MUST BE IN NEUTRAL MAY BE CRANKED IN JUMPER WIRE BETWEEN CONTINUE TEST
AND THE PARKING THE NEXT STEP. KEEP THE STARTER RLY NS-1A ON THE
BRAKE MUST BE ON AWAY FROM MOVING OUTPUT AND FUSED NEXT PAGE.
FOR THE NEXT STEP. ENGINE PARTS. B(+) CKTS. FIG.1
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TEST NS-1ACONTINUED - REPAIRING A NO CRANK CONDITION
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
TEST NS-1A
CONTINUED FROM DID THE STARTER YES CONTINUE TEST
THE PREVIOUS MOTOR CRANK THE NS-1A ON THE
PAGE. ENGINE? NEXT PAGE.
NO
DID THE STARTER
YES SOLENOID CLICK NO DISCONNECT THE
WHEN THE JUMPER JUMPER WIRE.
WIRE WAS
CONNECTED?
USING AN OHMMETER, DISCONNECT STARTER
MEASURE THE RELAY OUTPUT WIRE
STARTER RELAY FROM THE STARTER
OUTPUT CIRCUIT. SOLENOID.**
FIG.1 FIG.2
IS THE RESISTANCE NO REPAIR OPEN
BELOW 5.0 OHMS? STARTER RELAY
OUTPUT CKT.*
YES
CHECK THE BATTERY DID EITHER BATTERY
REINSTALL STARTER CABLES FOR HIGH CIRCUIT HAVE A YES REPAIR THE BATTERY
RELAY. RESISTANCE. (USE VOLTAGE DROP CIRCUIT FOR HIGH
SERVICE MANUAL GREATER THAN 0.2 RESISTANCE.*
PROCEDURE) VOLT?
NO
ATTEMPT TO
MANUALLY ROTATE IS THE CRANKSHAFT NO REPAIR ENGINE
THE CRANKSHAFT 360 ABLE TO ROTATE 360 MECHANICAL PROBLEM
DEGREES. DEGREES? AS NECESSARY.*
YES
REPLACE THE
STARTER MOTOR.*
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TEST NS-1ACONTINUED - REPAIRING A NO CRANK CONDITION
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
TEST NS-1A KEY OFF. WITH AN IS THE RESISTANCE
CONTINUED FROM OHMMETER, MEASURE BETWEEN NO REPLACE THE
THE PREVIOUS THE STARTER RELAY 60.0 AND 90.0 STARTER RELAY.*
PAGE. TERMINALS 85 AND 86. OHMS?
FIG.1
YES
KEY ON. USING A AT THE ECM HARNESS REPAIR THE STARTER
VOLTMETER, MEASURE CONNECTOR. IS THE VOLTAGE YES RELAY CONTROL CKT
STARTER RELAY ABOVE 1.0 VOLT? FOR A SHORT TO
CONTROL CKT... VOLTAGE.*
FIG.2
NO
WITH AN OHMMETER, BETWEEN THE ECM
MEASURE RESISTANCE HARNESS CONNECTOR IS THE RESISTANCE YES REPAIR THE OPEN
OF THE STARTER AND THE PDC ABOVE 5.0 OHMS? STARTER RELAY
RELAY CONTROLCONTROL CIRCUIT.*
CIRCUIT... FIG.2
NO
KEY ON. USING A WITH THE CLUTCH
VOLTMETER, MEASURE WHILE DEPRESSING DEPRESSED, IS THE YES REPLACE THE
THE CLUTCH THE CLUTCH. VOLTAGE ABOVE 10.0 STARTER RELAY.*
INTERLOCK SWITCH VOLTS?
CKT AT THE PDC)...
NO
KEY OFF. DISCONNECT MEASURE CLUTCH
THE CLUTCH INTERLOCK INTERLOCK SWITCH IS THE VOLTAGE NO REPAIR OPEN CLUTCH
SWITCH HARNESS HARNESS CONNECTOR ABOVE 10.0 VOLTS? INTERLOCK SWITCH
CONNECTOR. KEY ON. CAVITY 1. BATTERY SUPPLY.*
USING A VOLTMETER... FIG.3
YES
CONNECT A JUMPER PROBE THE CLUTCH
WIRE ACROSS THE INTERLOCK SWITCH IS THE VOLTAGE YES ADJUST OR REPLACE
CLUTCH INTERLOCK OUTPUT CKT. IN THE ABOVE 10.0 VOLTS? THE CLUTCH
SWITCH HARNESS PDC. INTERLOCK SWITCH.*
CONNECTOR. FIG.2
NO
REPAIR OPEN
CIRCUIT BETWEEN
STARTER RELAY AND
CLUTCH INTERLOCK
SWITCH.*
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TEST NS-2AREPAIRING A NO RESPONSE CONDITION
Perform TEST NS-SEL Before Proceeding
*Perform Verification TEST VER-1A. **Check connectors - Clean / repair as necessary.
START TEST DOES THE VEHICLE YES PERFORM TEST
NS-2A. START? NS-2B.
NO
KEY OFF. WITH AN OHMMETER, IS THE RESISTANCE
MEASURE RESISTANCE ABOVE 5.0 OHMS FOR YES REPAIR THE OPEN
DISCONNECT THE ECM OF THE PCM GND CKTS ANY OF THE ECM GROUND.*
HARNESS AT HARNESS CAVITIES MEASUREMENTS?
CONNECTORS.** 1 AND 27. FIG.1
NO
KEY ON. USING A AT ECM HARNESS REPAIR OPEN OR
VOLTMETER, MEASURE CONNECTOR CAVITY 47. IS THE VOLTAGE NO SHORT TO GROUND IN
THE FUSED IGNITION ABOVE 10.0 VOLTS? THE FUSED IGNITION
SWITCH OUTPUT SWITCH OUTPUT
CIRCUIT... FIG.1 CIRCUIT.*
YES
KEY OFF. USING A VOLTMETER REPAIR OPEN FUSE
REMOVE THE DIESEL PROBE DIESEL POWER IS THE VOLTAGE NO OR FUSED BATTERY
POWER RELAY. RELAY CONNECTOR ABOVE 10.0 VOLTS? CIRCUIT TO DIESEL
CAVITY 30 (IN PDC). POWER RELAY.*
KEY ON. FIG.2
YES
KEY OFF. CONNECT A MEASURE VOLTAGE AT IS THE VOLTAGE
JUMPER WIRE ACROSS ECM HARNESS ABOVE 10.0 VOLTS NO REPAIR OPEN DIESEL
RELAY CONNECTOR CONNECTOR CAVITIES FOR EACH POWER RELAY OUTPUT
CAVATIES 30 AND 87. 2 AND 28. MEASUREMENT? CIRCUIT(S).*
FIG. 1 AND 2
YES
KEY OFF. RECONNECT WITH JUMPER WIRE
THE ENGINE CONTROL STILL CONNECTED, DOES THE VEHICLE NO REPLACE THE ENGINE
MODULE HARNESS ATTEMPT TO START START? CONTROL MODULE.*
CONNECTORS. VEHICLE.
YES
CONTINUE TEST
NS-2A ON THE
NEXT PAGE.
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8.0 MAINTENANCE AND SERVICE INFORMATION
Refer to the appropriate service manual for information about repair and replacement procedures
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must
be corrected.
NOTE:If it is necessary to replace the body controller and the SKIM, perform the following steps
in order:
± program the new body controller
± program the new SKIM
± replace all ignition keys, program new ignition keys to new SKIM
NOTE:If it is necessary to replace the engine control module and the SKIM, perform the following
steps in order:
± program the new SKIM
± program the new engine control module
8.1 Programming the Engine Control Module
1. To program the VIN, connect the DRB and turn ignition on.
2. Select ªENGINEº from the main menu. The DRB will request the SKIS four-digit PIN.
3. Enter the PIN.
4. Select ªENTERº to update the VIN. The DRB will display the updated VIN.
5. If the engine is equipped with air conditioning, the ECM a/c function must be enabled.
± Using the DRB select ªENGINEº, ªMISCELLANEOUSº then ªENABLE/DISABLE A/Cº.
± Push 1 to enable A/C. DRB screen should display ªA/C Activatedº.
8.2 Programming the Body Control Module
The SKIS ªSecret Keyº is an I.D. code that is unique to each SKIM. This code is programmed and
stored in the SKIM, body controller and transponder chip (ignition keys). When replacing the BCM
it is necessary to program the secret key into the new BCM using the DRB. Perform the following
steps to program the secret key into the body controller.
1. Turn the ignition on (transmission in park/neutral).
2. Use the DRB and select ``THEFT ALARM'', ``SKIM'' then ``MISCELLANEOUS''.
3. Select ``GS DIESEL BCM REPLACED''.
4. SELECT ªENTERº to update BCM VIN.
5. Enter secured access mode by entering the vehicle four-digit PIN.
NOTE:If three attempts are made to enter secure access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN
position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also
monitor the battery state and connect a battery charger if necessary).
6. Press ªENTERº to transfer the secret key (the SKIM will send the secret key to the BCM).
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