2000 CHRYSLER CARAVAN immobilizer

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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TABLE OF CONTENTS - Continued
VERIFICATION TEST
VER-1ANO START VERIFICATION................................422
VER-2AROAD TEST VERIFICATION...............................423
VER-3ASPEED CONTROL VERIFICATION..........................424
8.0 MAINTENANCE AND SERVICE INFORMATION.............................425
8.1PROGRAMMING THE ENGINE CONTROL MODULE...................425
8.2PROGRAMMING THE BODY CONTROL MODULE.....................425
8.3PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE...........426
8.4PROGRAMMING IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER
MODULE.......................................................426
10.0 SCHEMATIC DIAGRAM.................................................427
11.0 REQUIRED TOOLS AND EQUIPMENT....................................428
12.0 GLOSSARY OF TERMS.................................................428
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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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After-Run- When fused ignition switch output is removed from the ECM cavity 47, the ECM
performs a self-diagnostic check in the following order:
1. Electrical shut-off test
2. Fuel quantity actuator test
3. Monitoring module test
4. Voltage regulator test
5. Main relay test (if tests 1-4 pass)
If any of tests 1-4 fail, the fault is stored in memory, and can be retrieved during the next ignition
cycle using the DRB.
3.2.3 Monitored Circuits
The ECM is able to monitor and identify most driveability related trouble conditions. Some circuits
are directly monitored through ECM feedback circuitry. In addition, the ECM monitors the voltage
state of some circuits and compares those states with expected values. Other systems are
monitored indirectly when the ECM conducts a rationality test to identify problems.
Although most subsystems of the powertrain control module are either directly or indirectly
monitored, there may be occasions when diagnostic trouble codes are not immediately identified.
For a trouble code to set, specific conditions must be met and unless these conditions are
encountered, a code will not set.
3.2.4 SKIS On-Board Diagnostics
The SKIS module has been programmed to transmit and monitor many different coded messages
as well as CCD Bus messages. This monitoring is called ``On-Board Diagnosis''.
Certain criteria must be met for a diagnostic trouble code to be entered into the Sentry Key
Immobilizer Module (SKIM) memory. The criteria may be a range of: input voltage, CCD Bus
messages, or coded messages to the SKIM. If all of the criteria for monitoring a circuit or function
are met and a fault is sensed, a diagnostic trouble code will be stored in the SKIM memory.
3.2.5 SKIS Overview
The Sentry Key Immobilizer System (SKIS) is an immobilizer system designed to prevent
unauthorized vehicle operation. The system consists of a Sentry Key Immobilizer Module (SKIM),
ignition key(s) equipped with a transponder chip, engine controller and body controller. When the
ignition switch is turned on, the SKIM interrogates the ignition key. If the ignition key is ªValidº the
SKIM sends a CCD Bus message to the body controller indicating the presence of a valid ignition
key. The BCM then supplies the ECM with a valid immobilizer signal allowing the engine to
continue to operate.
3.2.6 SKIS Operation
When ignition power is supplied to the SKIM, the SKIM performs an internal self-test. After the
self-test is completed, the SKIM energizes the antenna (this activates the transponder chip) and
sends a challenge to the transponder chip. The transponder chip responds to the challenge by
generating an encrypted response message using the following:
Secret Key þ This is an electronically stored value (identification number) that is unique to each
SKIS. The secret key is stored in the SKIM, BCM and all ignition key transponders.
Challenge þ This is a random number that is generated by the SKIM at each ignition key cycle.
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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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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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