2000 CHRYSLER CARAVAN engine coolant

TABLE OF CONTENTS - Continued
TC-42AREPAIRING - FAN CONTROL SHORT CIRCUIT FAN 2.........156
TC-43AREPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR
DEVIATION COLD.......................................160
TC-44AREPAIRING - FUEL QUANTITY ACTUATOR NEG. GOVERNOR
DEVIATION WARM.......................................164
TC-45AREPAIRING - FUEL QUANTITY ACTUATOR POS. GOVERNOR
DEVIATION COLD.......................................168
TC-46AREPAIRING - FUEL QUANTITY ACTUATOR POS. GOVERNOR
DEVIATION WARM.......................................172
TC-47AREPAIRING - FUEL TEMPERATURE SENSOR SRC HIGH
EXCEEDED.............................................176
TC-48AREPAIRING - FUEL TEMPERATURE SENSOR SRC LOW
EXCEEDED.............................................180
TC-51AREPAIRING - GLOW RELAY #1 CONTROLLER OPEN CIRCUIT .184
TC-52AREPAIRING - GLOW RELAY #2 CONTROLLER OPEN CIRCUIT .188
TC-53AREPAIRING - GLOW RELAY #1 CONTROLLER SHORT
CIRCUIT................................................192
TC-54AREPAIRING - GLOW RELAY #2 CONTROLLER SHORT
CIRCUIT................................................196
TC-56AREPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR DYNAMIC
PLAUSIBILITY...........................................200
TC-57AREPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR
OVERSPEED RECOGNITION..............................204
TC-58AREPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR
PLAUSIBILITY...........................................208
TC-59AREPAIRING - INDUCTIVE AUXILIARY SPEED SENSOR STATIC
PLAUSIBILITY...........................................212
TC-62AREPAIRING - INTAKE AIR TEMPERATURE SENSOR SIGNAL HIGH
EXCEEDED.............................................216
TC-63AREPAIRING - INTAKE AIR TEMPERATURE SENSOR SIGNAL LOW
EXCEEDED.............................................220
TC-72AREPAIRING - NEEDLE MOVEMENT SENSOR SRC HIGH
EXCEEDED.............................................224
TC-73AREPAIRING - NEEDLE MOVEMENT SENSOR SRC LOW
EXCEEDED.............................................228
TC-74AREPAIRING - REDUNDANT EMERGENCY STOP PLAUSIBILITY IN
AFTER-RUN............................................232
TC-75AREPAIRING - REDUNDANT EMERGENCY STOP POWERSTAGE
DEFECTIVE.............................................236
TC-76AREPAIRING - SMART START RELAY SHORT CIRCUIT.........240
TC-79AREPAIRING - SOLENOID VALVE CONTROLLER OPEN
CIRCUIT................................................242
TC-80AREPAIRING - SOLENOID VALVE CONTROLLER SHORT
CIRCUIT................................................246
TC-81AREPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH
EXCEEDED.............................................250
TC-82AREPAIRING - TEMPERATURE OF ENGINE COOLANT SRC LOW
EXCEEDED.............................................254
TC-84AREPAIRING - TERMINAL 15 PLAUSIBILITY AFTER START-UP . . .258
TC-85AREPAIRING - TIMING GOVERNING NEGATIVE GOVERNOR
DEVIATION.............................................262
iii
ProCarManuals.com

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
iv
ProCarManuals.com

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
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
6
ProCarManuals.com

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
G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
9
ProCarManuals.com

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.
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
21
ProCarManuals.com

TEST TC-81AREPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED
Perform TEST DTC Before Proceeding
FIG.1
FIG.2
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
250
ProCarManuals.com

TEST TC-81AREPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED
Perform TEST DTC Before Proceeding
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.
WITH THE DRB, READ IS THE ENGINE
START TEST THE ENGINE COOLANT COOLANT YES CONTINUE TEST
TC-81A. TEMPERATURE SENSOR TEMPERATURE SENSOR TC-81A ON THE
VOLTAGE. VOLTAGE ABOVE 4.7 NEXT PAGE.
VOLTS?
NO
USE THE SCHEMATIC WAS THERE ANY REPAIR THE HARNESS
AS A GUIDE AND MONITOR THE DRB ENGINE COOLANT YES OR CONNECTOR THAT
WIGGLE THE ECT DISPLAY. TEMPERATURE SENSOR CAUSED THE VOLTAGE
SENSOR CONNECTOR & VOLTAGE CHANGE? CHANGE.*
HARNESS. 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. FIG.2 WIRING AND
CONNECTORS.
NO
REFER TO GENERAL
INFOMATION 3.3.2 FOR YES
ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
251
ProCarManuals.com

TEST TC-81ACONTINUED - REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH
EXCEEDED
FIG.1
FIG.2
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
252
ProCarManuals.com