2001 DODGE TOWN AND COUNTRY check engine light

CONDITION POSSIBLE CAUSES CORRECTION
COOLANT LEVEL CHANGES IN
COOLANT BOTTLE.
TEMPERATURE GAUGE IS IN
NORMAL RANGE.1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
The coolant level will also drop as
the system removes air from a
recent filling.1. A normal condition. No repair is
necessary.
TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC).1. Normal reaction to fan and/or
thermostat cycle 1, Examples B
and C. During cold weather
operation with the heater blower in
the high position, the gauge reading
may drop slightly 1, Example D.
Fluctuation is also influenced by
outside temperature and heavy
loads 1, Example E.1. A normal condition. No correction
is necessary.
2. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running) 1,
Example F.2. A normal condition. No correction
is necessary. Gauge reading should
return to normal range 1, Example
A, after vehicle is driven.
3. Gauge reading high after
restarting a warmed-up (hot)
engine.3. A normal condition. No correction
is necessary. The gauge should
return to normal range 1, Example
A, after a few minutes of engine
operation.
4. Temperature gauge or engine
coolant temperature sensor
defective or shorted. Also, corroded
or loose wiring in the electrical
circuit.4. Check operation of gauge or
engine coolant temperature sensor
and repair, if necessary.
CLEANING
Drain cooling system and refill with clean water.
Refer to procedures in this section. Run engine with
radiator cap installed until upper radiator hose is
hot. Stop engine and drain water from system. If
water is dirty; fill, run, and drain system again, until
water runs clear.
INSPECTION
After performing a cleaning/flush procedure,
inspect all hoses, clamps and connections for deterio-
ration and leaks. Inspect radiator and heater core for
leaks.
COOLANT
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION
Coolant concentration should be checked when any
additional coolant was added to system or after a cool-
ant drain, flush and refill. The coolant mixture offers
optimum engine cooling and protection against corrosion
when mixed to a freeze point of -37ÉC (-34ÉF) to -59ÉC
(-50ÉF). The use of a hydrometer or a refractometer can
be used to test coolant concentration.
A hydrometer will test the amount of glycol in a
mixture by measuring the specific gravity of the mix-
ture. The higher the concentration of ethylene glycol,
the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of
60% by volume glycol).
RSENGINE7-17
ENGINE (Continued)
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A refractometer will test the amount of glycol in a
coolant mixture by measuring the amount a beam of
light bends as it passes through the fluid.
Some coolant manufactures use other types of gly-
cols into their coolant formulations. Propylene glycol
is the most common new coolant. However, propylene
glycol based coolants do not provide the same freez-
ing protection and corrosion protection and is not rec-
ommended.
CAUTION: Do not mix types of coolantÐcorrosion
protection will be severely reduced.
STANDARD PROCEDURE - COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAIN-
TENANCE SCHEDULES - DESCRIPTION).
COOLANT RECOVERY
CONTAINER
DESCRIPTION
The coolant recovery/reserve system container is
mounted in the engine compartment (Fig. 2). The
container is made of plastic.
OPERATION
The coolant recovery system works with the radia-
tor pressure cap to use thermal expansion and con-
traction of the coolant to keep the coolant free of
trapped air. Provides a convenient and safe method
for checking coolant level and adjusting level at
atmospheric pressure without removing the radiator
pressure cap. It also provides some reserve coolant to
cover deaeration, evaporation, or boiling losses.
Fig. 1 Temperature Gauge Indications
7 - 18 ENGINERS
COOLANT (Continued)
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DIAGNOSIS AND TESTING - COOLANT
RECOVERY SYSTEM
The cooling system is closed and designed to main-
tain coolant level to the top of the radiator.
(1) With the engineoffand cooling systemnot
under pressure, drain several ounces of coolant from
the radiator draincock while observing the coolant
recovery container. Coolant level in the container
should drop.
(2) Remove the radiator pressure cap. The coolant
level should be full to the top radiator neck. If not,
and the coolant level in the container is at or above
the MIN mark, there is an air leak in the coolant
recovery system.
(3) Check hose and hose connections to the con-
tainer, radiator filler neck or the pressure cap seal to
the radiator filler neck for leaks.
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the lower attaching screws (Fig. 2).
(3) Lower the vehicle.
(4) Remove the upper attaching screw (Fig. 2).
(5)
Disconnect recovery hose from container (Fig. 2).
(6) Remove the recovery container.
INSTALLATION
(1) Connect the recovery hose to container (Fig. 2).
(2) Position the recovery container on the frame
rail (Fig. 2).
(3) Install the upper attaching screw and tighten
to 7 N´m (60 in. lbs.) (Fig. 2).(4) Raise the vehicle on hoist.
(5) Install the lower attaching screws and tighten
to 8.5 N´m (75 in. lbs.) (Fig. 2).
(6) Lower the vehicle.
(7) Add coolant to container as necessary. (Refer to
7 - COOLING - STANDARD PROCEDURE)
ENGINE BLOCK HEATER
DESCRIPTION
The engine block heater is available as an optional
accessory on all models. The heater is operated by
ordinary house current (110 Volt A.C.) through a
power cord located behind the radiator grille. This
provides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures. The heater is mounted in a core
hole (in place of a core hole plug) in the engine block,
with the heating element immersed in coolant.
OPERATION
The block heater element is submerged in the cool-
ing system's coolant. When electrical power (110 volt
A.C.) is applied to the element, it creates heat. This
heat is transferred to the engine coolant. This pro-
vides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures.
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER
If unit does not operate, trouble can be in either
the power cord or the heater element. Test power
cord for continuity with a 110-volt voltmeter or 110-
volt test light; test heater element continuity with an
ohmmeter or 12-volt test light.
REMOVAL
(1) Drain coolant from radiator and cylinder block.
(Refer to 7 - COOLING - STANDARD PROCEDURE)
(2) Disconnect the power cord plug from heater.
(3) Loosen screw in center of heater. Remove the
heater assembly.
INSTALLATION
(1) Clean block core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward.
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Install power cord plug to heater.
(5) Fill cooling system with coolant to the proper
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
Fig. 2 COOLANT RECOVERY CONTAINER
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY/RESERVE CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
RSENGINE7-19
COOLANT RECOVERY CONTAINER (Continued)
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WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any
timeexceptfor the following purposes:
(1) Check and adjust coolant freeze point.
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTERCLOCK-
WISE TO THE FIRST STOP. ALLOW FLUIDS TO
ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS PUSH DOWN AND REMOVE THE CAP COM-
PLETELY. SQUEEZING THE RADIATOR INLET HOSE
WITH A SHOP TOWEL (TO CHECK PRESSURE)
BEFORE AND AFTER TURNING TO THE FIRST
STOP IS RECOMMENDED.
CLEANING
Use only a mild soap to clean the pressure cap.
INSPECTION
Hold the cap in your hand,top side up(Fig. 20).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.
Hold the cleaned cap in your hand,upside down.
If any light can be seen between vent valve and the
rubber gasket, replace the cap.Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
RADIATOR FAN
DESCRIPTION
The dual radiator fans are mounted to the back
side of the radiator (Fig. 21). The radiator fan consist
of the fan blade, electric motor and a support shroud
which are all serviced as an assembly.
Fig. 19 Radiator Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - PRESSURE BOTTLE
8 - FILLER NECK
Fig. 20 Cooling System Pressure Cap
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
8 - FILLER NECK
RSENGINE7-27
RADIATOR PRESSURE CAP (Continued)
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COOLING 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
COOLING 2.5L TURBO DIESEL
DESCRIPTION............................1
DIAGNOSIS AND TESTING..................1
COOLING SYSTEM......................1
COOLING SYSTEM LEAK TEST.............6
COOLING SYSTEM FLOW CHECK..........7COOLING SYSTEM AERATION.............7
CLEANING...............................7
INSPECTION.............................7
SPECIFICATIONS.........................8
ACCESSORY DRIVE.......................9
ENGINE................................14
COOLING 2.5L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible, maintains
normal operating temperature and prevents over-
heating.
The cooling system also provides a means of heat-
ing the passenger compartment. The cooling system
is pressurized and uses a centrifugal water pump to
circulate coolant throughout the system. A separate
and remotely mounted, pressurized coolant tank
using a pressure/vent cap is used.
COOLING SYSTEM COMPONENTS
The cooling system consists of:
²Charge Air Cooler
²Electric Cooling Fans
²A aluminum-core radiator with plastic side
tanks
²A separate pressurized coolant tank
²A pressure/vent cap on the coolant tank
²Fan shroud
²Thermostat
²Coolant
²Low coolant warning lamp
²Coolant temperature gauge
²Water pump
²Hoses and hose clamps
DIAGNOSIS AND TESTING - COOLING SYSTEM
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
(1) PROLONGED IDLE, VERY HIGH AMBIENT
TEMPERATURE, SLIGHT TAIL WIND AT IDLE,
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
OR STEEP GRADES.
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.
(2) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(3) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt
²Brakes (possibly dragging)
²Changed parts (incorrect water pump)
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only.
RGCOOLING 2.5L TURBO DIESEL7a-1
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CONDITION POSSIBLE CAUSES CORRECTION
6. Freeze point of antifreeze not
correct. Mixture may be too rich.6. Check antifreeze. Adjust
antifreeze-to-water ratio as
required.
7. Coolant not flowing through
system.7. Check for coolant flow in
coolant tank with engine warm
and thermostat open. Coolant
should be observed flowing
through the tank. If flow is not
observed, determine reason for
lack of flow and repair as
necessary.
8. Radiator or A/C condensor fins
are dirty or clogged.8. Clean debris from radiator or
A/C condensor
9. Radiator core is corroded or
plugged.9. Have radiator re-cored or
replaced.
10. Aftermarket A/C installed without
proper A/C condensor.10. Install proper A/C
condensor.
11. Dragging Brakes. 11. Check and correct as
necessary.
12. Non-factory bug screen is being
used reducing airflow.12. Only a factory screen
should be used.
13. Thermostat partially or
completely shut. This is more
prevalent on high mileage vehicles.13. Check thermostat and
replace if necessary.
14. Cylinder head gasket leaking. 14. Check cylinder head gasket
for leaks.
15. Heater core leaking. 15. Check heater cor for leaks.
Repair as necessary.
TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES
OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly. Fluctuation is also
influenced by loads, outside
temperature and extended idle time
with diesel engines.1. A normal condition. No
correction is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge
and repair as necessary.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running).3. A normal condition. No
correction needed. Gauge
should return to normal range
after vehicle is driven.
4. Gauge reading high after starting
a warm-iup (hot) engine.4. A normal condition. No
correction needed. Gauge
should return to normal after a
few minutes of engine
operation.
RGCOOLING 2.5L TURBO DIESEL7a-3
COOLING 2.5L TURBO DIESEL (Continued)
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100 Percent Ethylene-GlycolÐShould Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149 deg. C (300 deg. F). This temperature is hot
enough to melt plastic and soften solder. The
increased temperature can result in engine detona-
tion. In addition, 100 percent ethylene-glycol freezes
at -22 deg. C (-8 deg. F ).
Propylene-glycol FormulationsÐShould Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications.It's overall effec-
tive temperature range is smaller than that of ethyl-
ene-glycol. The freeze point of 50/50 propylene-glycol
and water is -32 deg. C (-26 deg. F). 5 deg. C higher
than ethylene-glycol's freeze point. The boiling point
(protection against summer boil-over) of propylene-
glycol is 125 deg. C (257 deg.F)at96.5 kPa (14 psi),
compared to 128 deg. C (263 deg. F) for ethylene-gly-
col. Use of propylene-glycol can result in boil-over or
freeze-up in Chrysler vehicles, which are designed for
ethylene-glycol. Propylene glycol also has poorer heat
transfer characteristics than ethylene glycol. This
can increase cylinder head temperatures under cer-
tain conditions.
Propylene-glycol/Ethylene-glycol MixturesÐShould Not Be
Used in Chrysler Vehicles
Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene glycol.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING
Coolant concentration should be checked when any
additional coolant was added to system or after a
coolant drain, flush and refill. The coolant mixture
offers optimum engine cooling and protection against
corrosion when mixed to a freeze point of -37ÉC
(-34ÉF) to -59ÉC (-50ÉF). The use of a hydrometer or a
refractometer can be used to test coolant concentra-
tion.
A hydrometer will test the amount of glycol in a
mixture by measuring the specific gravity of the mix-
ture. The higher the concentration of ethylene glycol,
the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of
60% by volume glycol).
A refractometer will test the amount of glycol in a
coolant mixture by measuring the amount a beam of
light bends as it passes through the fluid.
Some coolant manufactures use other types of gly-
cols into their coolant formulations. Propylene glycol
is the most common new coolant. However, propylene
glycol based coolants do not provide the same freez-
ing protection and corrosion protection and is not rec-
ommended.
CAUTION: Do not mix types of coolantÐcorrosion
protection will be severely reduced.
STANDARD PROCEDURE - COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAIN-
TENANCE SCHEDULES - DESCRIPTION).
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The pressure/vent cap should not be removed
from the coolant recovery pressure container.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery pres-
sure container (Fig. 1). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
RGENGINE7a-15
COOLANT (Continued)
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FASTEN SEAT BELT LAMP OR TONE CONTINUES
FOR MORE THAN 10 SECONDS AFTER SEAT
BELTS ARE FASTENED AND DRIVER'S DOOR IS
CLOSED.
Refer to the proper Body Diagnostic Procedures
manual.
NO TONE WHEN PARK OR HEADLAMPS ARE ON
AND DRIVER'S DOOR IS OPEN.
Make sure ignition is in lock position with the key
removed.
(1) Check the BCM DTC's and BCM sensors to
verify the door is open. Repair as necessary.
(2) Actuate Chime (BCM actuates).
(3) Inspect BCM connectors and wires for proper
connection.
(4) Measure with a voltmeter the voltage (12v) on
BCM connector (PX2) pin 34 with harness connected.
DIAGNOSIS AND TESTING - DOME LAMP ON
CHIME
The dome lamp on chime will warn the driver that
the dome lamps have been left on.
When the ignition is OFF:
²Driver's door OPEN (door ajar switch is closed to
ground) and
²Dome lamps are ON (dome lamp switch is closed
to ground),
The chime will sound continuously until driver's
door is closed, dome lamps tuned OFF or until the
battery protection time out of 15 minutes has
expired. Chime rate: 168 to 192 chimes per minute.
DIAGNOSIS AND TESTING - ENGINE
TEMPERATURE CRITICAL CHIME
The engine temperature critical chime will warn
the driver that the vehicle's engine is overheating.
While monitoring the coolant temperature, the Pow-
ertrain Control Module (PCM) will send on the PCI
data bus as engine temperature every 1.376 seconds
to the cluster. The MIC calculates engine tempera-
ture and determines if a warning should occur. This
feature is functional only with the Ignition Switch in
the Run/Start position.
When the engine temperature reaches 122ÉC
(252ÉF) the MIC requests a chime from the BCM and
the engine temperature lamp comes ON. The MIC
turns OFF the lamp when the engine temperature
reaches 117ÉC (242ÉF). The MIC will chime continu-
ously (request from the BCM). The chime will turn
OFF after four minutes or when the temperature
reaches 117ÉC (242ÉF), which ever occurs first.
DIAGNOSIS AND TESTING - EXTERIOR LAMPS
ON CHIME
The exterior lamp on chime will warn the driver
that the exterior lights have been left on.
With the ignition switch OFF/key out of ignition:
²Driver's door is open (door ajar switch is closed
to ground)
²Parking lamps or headlamps ON (parking lamp
switch is closed to ground)
The chime will sound until lights are turned OFF,
driver's door closed or until the battery protection
time out of 3 minutes has expired.
Chime rate: 168 to 192 chimes per minute.
To test the exterior lamps left on function:
²Turn ignition off
²Remove ignition key
²Turn exterior lamps on with driver's door open.
Chime should sound until lamps are turned off or
driver's door is closed.
DIAGNOSIS AND TESTING - KEY-IN IGNITION
CHIME
The key-in ignition chime will act as a warning to
the driver that the ignition key has been left in the
ignition switch.
With the ignition switch is in OFF position ONLY:
²Driver's door is open/ajar (door ajar switch is
closed to ground)
²Key is in the ignition switch (ignition is in the
LOCK position)
The chime will sound until one of the above condi-
tions is removed or until battery protection time out
(15 min.) has expired. Chime rate: 168 to 192 chimes
per minute.
To test the key-in ignition function, insert key into
the ignition and open driver's door. Do not turn igni-
tion ON. Chime should sound until key is removed
from ignition or driver's door is closed.
For diagnosis and testing of the Key-In Accessory
chime, use the same testing procedure as above but
with the key in the accessory position.
DIAGNOSIS AND TESTING - LOW OIL
PRESSURE CHIME
The low oil pressure chime will warn the driver
that the engine oil pressure is low. The oil pressure
switch will close to ground during a low oil pressure
condition. The oil pressure lamp will illuminate in
the message center. The PCM will monitor the oil
pressure switch and signal a low oil pressure condi-
tion. A continuous four minute warning chime will
sound and the oil pressure lamp will come ON when
the following conditions are met:
²Ignition on and engine not cranking
8B - 2 CHIME/BUZZERRS
CHIME/BUZZER (Continued)
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