2000 CHRYSLER VOYAGER immobilizer

TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1SYSTEM COVERAGE...............................................1
1.2SIX-STEP TROUBLESHOOTING PROCEDURE..........................1
2.0 IDENTIFICATION OF SYSTEM.............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION......................1
3.1GENERAL DESCRIPTION............................................1
3.2FUNCTION OPERATION.............................................1
3.2.1FUEL CONTROL.............................................1
3.2.2ON-BOARD DIAGNOSTICS....................................2
3.2.3OTHER CONTROLS..........................................4
3.2.4PCM OPERATING MODES....................................4
3.2.5NON-MONITORED CIRCUITS..................................5
3.2.6SKIS OVERVIEW............................................5
3.2.7SKIM ON-BOARD DIAGNOSTICS...............................5
3.2.8SKIS OPERATION............................................6
3.2.9PROGRAMMING THE POWERTRAIN CONTROL MODULE..........6
3.2.10PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE.......7
3.2.11PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY
IMMOBILIZER MODULE.......................................7
3.3DIAGNOSTIC TROUBLE CODES......................................7
3.3.1HARD CODE................................................7
3.3.2INTERMITTENT CODE........................................8
3.3.3RESET COUNTER...........................................8
3.3.4HANDLING NO TROUBLE CODE PROBLEMS....................8
3.4USING THE DRBIIIT................................................11
3.5DRB ERROR MESSAGES AND BLANK SCREEN........................11
3.5.1DRB IIITDOES NOT POWER UP..............................11
3.5.2DISPLAY IS NOT VISIBLE....................................11
4.0 DISCLAIMERS, SAFETY, WARNINGS......................................11
4.1DISCLAIMERS.....................................................11
4.2SAFETY..........................................................11
4.2.1TECHNICIAN SAFETY INFORMATION..........................11
4.2.2VEHICLE PREPARATION FOR TESTING........................12
4.2.3SERVICING SUB-ASSEMBLIES...............................12
4.2.4DRBIIITSAFETY INFORMATION...............................12
4.3WARNINGS AND CAUTIONS........................................12
4.3.1ROAD TEST WARNINGS.....................................12
4.3.2VEHICLE DAMAGE CAUTIONS...............................12
4.3.3ELECTRONIC PINION FACTOR WARNING......................13
5.0 RECOMMENDED TOOLS AND EQUIPMENT................................13
6.0 GLOSSARY OF TERMS..................................................13
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES...........................15
CHARGING
P-0622 GENERATOR FIELD NOT SWITCHING PROPERLY....................16
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TABLE OF CONTENTS - Continued
SPEED CONTROL
P-1595 SPEED CONTROL SOLENOID CIRCUITS...........................256
P-1683 SPEED CONTROL POWER RELAY OR S/C 12V DRIVER..............256
SPEED CONTROL BRAKE SWITCH OUTPUT..............................261
SPEED CONTROL DENIED MESSAGE....................................263
SPEED CONTROL ON/OFF SWITCH......................................264
* CHECKING SPEED CONTROL OPERATION..............................266
STARTING
*9NO RESPONSE9CONDITION..........................................272
* CHECKING THE CAM AND CRANK SENSORS............................276
* CHECKING THE ENGINE MECHANICAL SYSTEMS........................277
* CHECKING THE FUEL SYSTEM........................................278
* CHECKING THE IDLE AIR CONTROL MOTOR.............................287
* CHECKING THE SECONDARY IGNITION SYSTEM.........................288
* NO CRANK CONDITION...............................................296
* START AND STALL CONDITION.........................................301
TRANSMISSION
P-0740 TORQUE CONV CLUTCH, NO RPM DROP AT LOCKUP...............302
P-0743 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT................304
P-1899 PARK/NEUTRAL SWITCH STUCK IN PARK OR IN GEAR..............307
ANTENNA FAILURE....................................................310
COP FAILURE.........................................................310
EEPROM FAILURE.....................................................310
INTERNAL FAULTS.....................................................310
RAM FAILURE.........................................................310
SERIAL LINK INTERNAL................................................310
STACK OVERFLOW FAILURE............................................310
SENTRY KEY IMMOBILIZER SYSTEM
PCM STATUS FAILURE.................................................311
ROLLING CODE FAILURE...............................................311
SERIAL LINK EXTERNAL FAULT..........................................311
TRANSPONDER COMMUNICATION FAILURE..............................313
TRANSPONDER ID MISMATCH..........................................313
TRANSPONDER RESPONSE MISMATCH..................................313
VIN MISMATCH........................................................315
VERIFICATION TESTS
VERIFICATION TESTS..................................................317
8.0 COMPONENT LOCATIONS..............................................323
8.1CONTROL MODULES AND PDC.....................................323
8.2CONTROLS & SOLENOIDS.........................................323
8.3DATA LINK CONNECTOR..........................................327
8.4SENSORS.......................................................327
8.5FUEL SYSTEM...................................................330
8.6SWITCHES......................................................331
8.7SPECIFICATIONS.................................................332
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TABLE OF CONTENTS - Continued
ENGINE STARTER MOTOR RELAY.......................................347
FRONT BLOWER MOTOR RELAY........................................347
FUEL HEATER RELAY (DIESEL)..........................................347
FUEL PUMP RELAY (GAS)..............................................347
HIGH BEAM RELAY....................................................347
HORN RELAY.........................................................347
LOW BEAM RELAY....................................................348
PARK LAMP RELAY....................................................348
TRANSMISSION CONTROL RELAY (EATX).................................348
WIPER HIGH/LOW RELAY...............................................348
WIPER ON RELAY.....................................................348
POWERTRAIN CONTROL MODULE C1 - BLACK 40 WAY.....................349
POWERTRAIN CONTROL MODULE C2 - GRAY 40 WAY......................350
RADIATOR FAN NO. 1 - BLACK 2 WAY....................................350
RADIATOR FAN NO 2 - BLACK 2 WAY....................................351
RADIATOR FAN RELAY - BLACK 4 WAY...................................351
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY......................351
THROTTLE POSITION SENSOR (2.0L) - BLACK 3 WAY......................351
THROTTLE POSITION SENSOR (EXCEPT 2.0L) - NATURAL 3 WAY............352
TORQUE CONVERTER CLUTCH SOLENOID (ATX)-3WAY..................352
TRANSMISSION CONTROL MODULE - BLACK 60 WAY......................353
TRANSMISSION RANGE SENSOR - GRAY 10 WAY.........................354
TRANSMISSION SOLENOID/PRESSURE SWITCH - BLACK 8 WAY............354
VEHICLE SPEED CONTROL SERVO - BLACK 4 WAY........................354
VEHICLE SPEED SENSOR (EXCEPT 3.3L/3.8L) - BLACK 3 WAY..............354
10.0 SCHEMATIC DIAGRAMS................................................355
10.12000 GS 2.0L AND 2.4L ENGINES...................................355
10.22000 GS 3.0L ENGINE...........................................356
10.32000 GS 3.3L and 3.8L ENGINES................................................................357
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The PCM determines the spark advance based on
the following:
± engine coolant temperature
± crankshaft position
± camshaft position
± intake air temperature
± manifold absolute pressure
± throttle position
Engine Warm-Up Mode -This is an open loop-
mode. The PCM adjusts injector pulse width and
controls injector synchronization by controlling the
fuel injectors' ground paths. The PCM adjusts igni-
tion timing and engine idle speed. The PCM adjusts
the idle speed by controlling the idle air control
motor and spark advance.
Cruise or Idle Mode -When the engine is at
normal operating temperature, this is a closed loop
mode.
Acceleration Mode -This is a closed loop mode.
The PCM recognizes an increase in throttle position
and a decrease in manifold vacuum as engine load
increases. In response, the PCM increases the in-
jector pulse width to meet the increased load. The
A/C compressor may be de-energized for a short
period of time.
Deceleration -This is a closed loop mode. The
PCM recognizes a decrease in throttle position and
an increase in manifold vacuum as engine load
decreases. In response, the PCM decreases the
injector pulse width to meet the decreased load.
Full injector shut off may be obtained during high
speed deceleration.
Wide Open Throttle Mode -This is an open
loop mode. The throttle position sensor notifies the
PCM of a wide open throttle condition. Once a wide
open throttle is sensed, the PCM de-energizes the
A/C compressor clutch relay for 15 seconds.
3.2.5 NON-MONITORED CIRCUITS
The PCM does not monitor the following circuits,
systems, and conditions even though they could
have malfunctions that result in driveability prob-
lems. A diagnostic code may not be displayed for the
following conditions. However, problems with these
systems may cause a diagnostic code to be displayed
for other systems. For example, a fuel pressure
problem will not register a diagnostic code directly,
but could cause a rich or lean condition. This could
cause an oxygen sensor, fuel system, or misfire
monitor trouble code to be stored in the PCM.
Engine Timing -The PCM cannot detect an
incorrectly indexed timing chain, camshaft
sprocket, or crankshaft sprocket. The PCM also
cannot detect an incorrectly indexed distributor.(*)
Fuel Pressure -Fuel pressure is controlled by
the fuel pressure regulator. The PCM cannot detecta clogged fuel pump inlet filter, clogged in-line filter,
or a pinched fuel supply.(*)
Fuel Injectors -The PCM cannot detect if a fuel
injector is clogged, the pintle is sticking, or the
wrong injectors are installed.(*)
Fuel Requirements -Poor quality gasoline can
cause problems such as hard starting, stalling, and
stumble. Use of methanol-gasoline blends may re-
sult in starting and driveability problems. See indi-
vidual symptoms and their definitions in Section
6.0 (Glossary of Terms)
PCM Grounds -The PCM cannot detect a poor
system ground. However, a diagnostic trouble code
may be stored in the PCM as a result of this
condition.
Throttle Body Air Flow -The PCM cannot
detect a clogged or restricted air cleaner inlet or
filter element.(*)
Exhaust System -The PCM cannot detect a
plugged, restricted, or leaking exhaust system.(*)
Cylinder Compression -The PCM cannot de-
tect uneven, low, or high engine cylinder compres-
sion.(*)
Excessive Oil Consumption -Although the
PCM monitors the exhaust stream oxygen content
through the oxygen sensor when the system is in a
closed loop, it cannot determine excessive oil con-
sumption.
(*)NOTE: ANY OF THESE CONDITIONS
COULD RESULT IN A RICH OR LEAN
CONDITION CAUSING AN OXYGEN SENSOR
TROUBLE CODE TO BE STORED IN THE
PCM, OR THE VEHICLE MAY EXHIBIT ONE
OR MORE OF THE DRIVEABILITY
SYMPTOMS LISTED IN THE TABLE OF
CONTENTS.
3.2.6 SKIS OVERVIEW
The Sentry Key Immobilizer System (SKIS) is an
immobilizer system design to prevent unauthorized
vehicle operation. The system consists of a Sentry
Key Immobilizer Module (SKIM), ignition key(s)
equipped with a transponder chip and engine con-
troller. When the ignition switch is turned on, the
SKIM interrogates the ignition key. If the ignition
key is ``Valid'', the SKIM sends a CCD Bus message
to the engine controller indicating the presence of a
valid igntion key. Upon receiving a ``Valid'' key
signal the PCM will allow the engine to continue to
operate.
3.2.7 SKIM ON-BOARD DIAGNOSTICS
The SKIM has been programmed to transmit and
monitor many different coded messages as well as
CCD Bus messages. This monitoring is called ``On
Board Diagnosis''.
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NOTE:IF THREE ATTEMPTS ARE MADE TO
ENTER THE 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).
5. Press ``ENTER'' to transfer the secret key (the
SKIM will send the secret key to the PCM).
3.2.10 PROGRAMMING THE SENTRY KEY
IMMOBILIZER MODULE
NOTE:IF THE PCM AND THE SKIM ARE
REPLACED AT THE SAME TIME, PROGRAM
THE VIN INTO THE PCM FIRST. ALL VEHICLE
KEYS WILL THEN NEED TO BE REPLACED
AND PROGRAMMMED TO THE NEW SKIM.
1. Turn the ignition on (transmission in park/
neutral).
2. Use the DRB and select ``THEFT ALARM'',
``SKIM'' then MISCELLLANEOUS.
3. Select ``SKIM MOSULE REPLACEMENT (GAS-
OLINE)''
4. Program the vehicle four-digit PIN into the
SKIM.
5. Select ``COUNTRY CODE'' and enter the correct
country.
NOTE:BE SURE TO ENTER THE CORRECT
COUNTRY CODE. IF THE INCORRECT
COUNTRY CODE IS PROGRAMMED INTO
SKIM, THE SKIM MUST BE REPLACED.
6. Select ``UPDATE VIN'' (the SKIM will learn the
VIN from the PCM).
7. Press ``ENTER'' to transfer the VIN (the PCM
will send the VIN to the SKIM).
8. The DRB will ask if you want to transfer the
secret key. Select ``ENTER'' to transfer secret key
from the PCM. This will ensure the current
vehicle ignition keys will still operate the SKIS
system.
3.2.11 PROGRAMMING THE IGNITION
KEYS TO THE SENTRY KEY
IMMOBILIZER MODULE
1. Turn the ignition on (transmission in park/
neutral).2. Use the DRB and select ``THEFT ALARM'',
``SKIM'' then ``MISCELLANEOUS''.
3. Select ``PROGRAM IGNITION KEYS''.
4. Enter secured access mode by entering the vehi-
cle four-digit PIN.
NOTE:A MAXIMUM OF EIGHT KEYS CAN BE
LEARNED TO EACH SKIM. ONCE A KEY IS
LEARNED TO A SKIM IT (THE KEY) CANNOT
BE RANFERRED TO ANOTHER VEHICLE.
If ignition key programming is unsuccessful, the
DRB will display one of the following messages:
Programming Not Attempted -The DRB at-
tempts to read the programmed key status and
there are no keys programmmed in the SKIM
memory.
Programming Key Failed -(Possible Used Key
From Wrong Vehicle) - SKIM is unable to program
key due to one of the following:
- faulty ignition key transponder
- ignition key is programmed to another vehicle.
8 Keys Already Learned, Programming Not
Done -SKIM transponder ID memory is full.
1. Obtain ignition keys to be programmed from
customer (8 keys maximum)
2. Using the DRB, erase all ignition keys by select-
ing ``MISCELLANEOUS'' and ``ERASE ALL
CURRENT IGN. KEYS''
3. Program all ignition keys.
Learned Key In Ignition -Ignition key tran-
sponder ID is currently programmed in SKIM mem-
ory.
3.3 DIAGNOSTIC TROUBLE CODES
Each diagnostic trouble code is diagnosed by
following a specific testing procedure. The diagnos-
tic 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 DRBIIIt.
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
powertrain control module checks that circuit or
function. Procedures in this manual verify if the
trouble code is a hard code at a the beginning of
each test. When it is not a hard code, an ªintermit-
tentº test must be performed.
Codes that are for Euro Stage III OBD monitors will
not set with just the ignition key on. Comparing these
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4.3.3 ELECTRONIC PINION FACTOR
WARNING
The pinion factor must be set for all new trans-
mission control modules. If the pinion factor is not
set or if it is set incorrectly, any speed-related
accessories will not operate or will operate inaccu-
rately. This includes the speedometer, speed con-
trol, rolling door locks, and other devices that are
operated by the powertrain and body control mod-
ules. For instructions on setting the pinion factor,
see the appropriate transmission diagnostic man-
ual or the service manual.
5.0 RECOMMENDED TOOLS
AND EQUIPMENT
DRBIIIt(diagnostic readout box) scan tool
fuel pressure adapter (C-6631) or #6539
fuel pressure kit (C-4799-B) or #5069
fuel release hose (C-4799-1)
MinAir flow fitting #6457
jumper wires
ohmmeter
oscilloscope
vacuum gauge
voltmeter
12 volt test light minimum 25 ohms resistance
with probe #8382
CAUTION: A 12 VOLT TEST LIGHT SHOULD
NOT BE USED FOR THE FOLLOWING
CIRCUITS, DAMAGE TO THE POWERTRAIN
CONTROLLER WILL OCCUR.
²5 Volt Supply
²8 Volt Supply
²J1850 PCI Bus
²CCD Bus
²CKP Sensor Signal
²CMP Sensor Signal
²Vehicle Speed Sensor Signal
²O2 Sensor Signal
6.0 GLOSSARY OF TERMS
ABSantilock brake system
backfire,
popbackfuel ignites in either the intake or
the exhaust system
CKPcrank position sensor
CMPcamshaft position sensor
cuts out,
missesa steady pulsation or the inability of
the engine to maintain a consistent
rpmDLCdata link connector (previously
called ªengine diagnostic connectorº)
detona-
tion,
spark
knocka mild to severe ping, especially un-
der loaded engine conditions
ECTengine coolant temperature sensor
EGRexhaust gas recirculation valve and
system
genera-
torpreviously called ªalternatorº
hard
startThe engine takes longer than usual
to start, even though it is able to
crank normally.
hesita-
tion, sag,
stumble
There is a momentary lack of response
when the throttle is opened.
This can
occur at all vehicle speeds. If it is se-
vere enough, the engine may stall.
IATintake air temperature sensor
IACidle air control valve
JTECCombined engine and transmission
control module
lack of
power,
sluggish
The engine has less than expected
power, with little or no increase in vehi-
cle speed when the throttle is opened.
LDPLeak Detection Pump
MAPmanifold absolute pressure sensor
MILmalfunction indicator lamp
MTVmanifold tuning valve
O2Soxygen sensor
PCIProgrammable Communication In-
terface
PCMpowertrain control module
PCMpowertrain control module
PCVpositive crankcase ventilation
PEPPeripheral Expansion Port
poor fuel
economyThere is significantly less fuel mile-
age than other vehicles of the same
design and configuration
rough,
unstable,
or er-
ratic idle
stallingThe engine runs unevenly at idle
and causes the engine to shake if it
is severe enough. The engine idle
rpm may vary (called ªhuntingº).
This condition may cause stalling if
it is severe enough.
SKIMSentry Key Immobilizer Module
SKISSentry Key Immobilizer System
start and
stallThe engine starts but immediately
dies.
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Symptom List:
ANTENNA FAILURE
COP FAILURE
EEPROM FAILURE
INTERNAL FAULTS
RAM FAILURE
SERIAL LINK INTERNAL
STACK OVERFLOW FAILURE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be ANTENNA FAILURE.
When Monitored and Set Condition:
EEPROM FAILURE
When Monitored: At ignition ON and during the SKIM programming process, which
programs SKIM's PIN the VIN, country code or additional keys.
Set Condition: This condition is set when an error occurs during programming the
SKIM's EEPROM. The other condition that causes this code to mature is an EEPROM I2C
link failure.
POSSIBLE CAUSES
SKIM INTERNAL DTC FAILURE
TEST ACTION APPLICABILITY
1Note: This trouble code indicates an internal SKIM fault.
With the DRBIIIt, read and record SKIM DTC's and then erase SKIM DTC's
Perform several key cycles, leaving the key on for a minimum of 30 seconds per cycle.
With the DRBIIIt, read SKIM trouble codes.
Did the SKIM Internal DTC return?All
Ye s®Replace the Sentry Key Immobilizer Module.
Perform the Powertrain Verification Test VER-7A.
No®Test Complete.
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TRANSMISSION
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Symptom List:
PCM STATUS FAILURE
ROLLING CODE FAILURE
SERIAL LINK EXTERNAL FAULT
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be PCM STATUS FAILURE.
When Monitored and Set Condition:
PCM STATUS FAILURE
When Monitored: This condition is monitored at ignition ON and continuously during an
ignition ON cycle.
Set Condition: This condition exists when a PCM STATUS bus message was not received
from the PCM. Note: Failure maturity time is 20 seconds.
ROLLING CODE FAILURE
When Monitored: At ignition ON, after ignition ON during any rolling code handshake
that occurs with the PCM due to a SKIM or a PCM reset.
Set Condition: This condition exists when a PCM STATUS message is not received by the
SKIM within 3.5 seconds of transmitting what the SKIM believes to be a 'key code'
message to the PCM. the 'key code' sent by the SKIM may or may not be valid in this case.
SERIAL LINK EXTERNAL FAULT
When Monitored: At ignition ON, after ignition ON during any rolling code handshake
that occurs with the PCM due to a SKIM reset or a PCM reset, or during 'Secret Key'
transfers to the PCM.
Set Condition: This condition is set when the SKIM does not receive an expected bus
message transmission acknowledgement from the PCM after 3 transmit attempts.
POSSIBLE CAUSES
INTERMITTENT WIRING HARNESS PROBLEM
WIRING HARNESS INSPECTION
SKIM/PCM DEFECTIVE
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SENTRY KEY IMMOBILIZER SYSTEM
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