2000 CHRYSLER CARAVAN air condition

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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1.0 INTRODUCTION
The procedures contained in this manual include all the specifications, instructions, and graphics
needed to diagnose engine control module (ECM) and sentry key immobilizer system (SKIS)
problems; they are no start, diagnostic trouble code, and no trouble code problems for the ECM.
The diagnostics in this manual are based on the trouble condition or symptom being present at
the time of diagnosis.
When repairs are required, refer to the appropriate volume of the service manual for proper
removal and repair procedure.
Diagnostic procedures change every year. New diagnostic systems may be added; carryover
systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE MANUAL
TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES.
This manual is designed to begin all diagnosis at the DTC TEST, which is located at the beginning
of Section 7.1. This will cover all the necessary requirements to begin a logical diagnostic path for
each problem. If there is a diagnostic trouble code (DTC) detected, it will direct you to the trouble
code test. If there are no trouble codes present, it will direct you by symptom to a no-trouble code
test.
This book reflects many suggested changes from readers of past issues. After using this book, if
you have any comments or recommendations, please fill out the form at the back of the book and
mail it back to us.
1.1 System Coverage
This diagnostic procedures manual covers all 2000 GS body equipped with the 2.5L VM diesel
engine.
1.2 Six-Step Troubleshooting Procedure
Diagnosis of the engine control module (ECM) and SKIS is done in six basic steps:
²verification of complaint
²verification of any related symptoms
²symptom analysis
²problem isolation
²repair of isolated problem
²verification of proper operation
2.0 IDENTIFICATION OF SYSTEM
The engine control module (ECM) is located in the center of the passenger compartment behind
the lower console. The sentry key immobilizer module is located below the steering column
behind the steering wheel.
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
3.1 General Description
The 2.5L VM diesel engine system is equipped with the latest in technical advances. The
on-board diagnostics incorporated with the engine control module and SKIM are intended to
assist the field technician in repairing vehicle problems by the quickest means.
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²Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
²Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 - 1.12 megohms
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100É F
-50 - 600É C
* Ohms cannot be measured if voltage is
present. Ohms can be measured only in a
non-powered circuit.
²Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
²Use caution when measuring voltage above 25v DC or 25v AC.
²The circuit being tested must be protected by a 10A fuse or circuit breaker.
²Use the low current shunt to measure circuits up to 10A. Use the high current clamp to
measure circuits exceeding 10A.
²When testing for the presence of voltage or current, make sure the meter is functioning
correctly. Take a reading of a known voltage or current before accepting a zero reading.
²When measuring current, connect the meter in series with the load.
²Disconnect the live test lead before disconnecting the common test lead.
5.3 Warnings
5.3.1 Vehicle Damage Warnings
Before disconnecting any control module, make sure the ignition is ``off''. Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end)
of the connector. Do not probe a wire through the insulation; this will damage it and eventually
cause it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, other codes could be set, making diagnosis of
the original problem more difficult.
5.3.2 Road Testing a Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled.
During the test drive, do not try to read the DRB screen while in motion. Do not hang the
DRB from the rear view mirror or operate it yourself. Have an assistant available to operate
the DRB.
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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-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-3AREPAIRING - A/C SYSTEM PRESSURE SIGNAL HIGH EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN A/C ON.
START TEST WITH THE DRB, READ IS THE A/C OUTPUT YES CONTINUE TEST
TC-3A. THE A/C OUTPUT VOLTAGE ABOVE TC-3A ON THE
VOLTAGE. 4.8 VOLTS? NEXT PAGE.
NO
USE THE SCHEMATIC AS REPAIR THE HARNESS
A GUIDE AND WIGGLE MONITOR THE DRB WAS THERE ANY A/C YES OR CONNECTOR THAT
A/C PRESSURE SENSOR DISPLAY. OUTPUT VOLTAGE CAUSED THE VOLTAGE
CONNECTOR & HARNESS. CHANGE? CHANGE.*
FIG.1
NO
AT THIS TIME, THE USING THE
CONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
TO SET THE CODE IS GUIDE, INSPECT THE FOUND? NECESSARY.*
NOT PRESENT. WIRING AND
FIG.2 CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-4AREPAIRING - A/C SYSTEM PRESSURE SIGNAL LOW EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN A/C ON.
START TEST WITH THE DRB, READ IS THE A/C OUTPUT YES CONTINUE TEST
TC-4A. THE A/C OUTPUT VOLTAGE BELOW 0.2 TC-4A ON THE
VOLTAGE. VOLT? NEXT PAGE.
NO
USE THE SCHEMATIC AS REPAIR THE HARNESS
A GUIDE AND WIGGLE MONITOR THE DRB WAS THERE ANY A/C YES OR CONNECTOR THAT
A/C PRESSURE SENSOR DISPLAY. OUTPUT VOLTAGE CAUSED THE VOLTAGE
CONNECTOR & HARNESS. CHANGE? CHANGE.*
FIG.1
NO
AT THIS TIME, THE USING THE
CONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
TO SET THE CODE IS GUIDE, INSPECT THE FOUND? NECESSARY.*
NOT PRESENT. WIRING AND
FIG.2 CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
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TEST TC-5AREPAIRING - A/C SYSTEM PRESSURE SUPPLY HIGH EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
TURN IGNITION ON. DOES THE DRB
START TEST WITH THE DRB, DISPLAY "A/C YES CONTINUE TEST
TC-5A. ERASE CODES. SYSTEM PRESSURE TC-5A ON THE
SUPPLY HIGH NEXT PAGE.
TURN A/C ON. EXCEEDED"?
NO
WIGGLE THE A/C DOES THE DRB REPAIR THE
PRESSURE SENSOR MONITOR THE DRB DISPLAY "A/C YES CONNECTOR OR
CONNECTOR AND DISPLAY. SYSTEM PRESSURE HARNESS WIRES THAT
HARNESS WIRES. SUPPLY HIGH"? CAUSED THE CODE TO
SET.*
NO
AT THIS TIME THE USING THE
CONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
TO SET THIS CODE GUIDE, INSPECT THE FOUND? NECESSARY.*
IS NOT PRESENT. WIRING AND
CONNECTORS.
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES. FIG.1
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