Chrysler Town, Dodge Caravan. Manual — part 1114
TABLE OF CONTENTS - Continued
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION . . . . . . . . . . . . . . . . . . .209
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION . .216
*CHECKING THE ENGINE MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . .217
*CHECKING THE GLOW PLUG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
*CHECKING THE LIFT PUMP MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .220
*CHECKING THE MAF SENSOR CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
*CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .225
*CHECKING THE VEHICLE SPEED SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
*ENGINE CRANKS BUT WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
*ENGINE WILL NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
SENTRY KEY IMMOBILIZER - BUX DSL
ANTENNA FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
COP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
EEPROM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
RAM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
SERIAL LINK INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
PCM STATUS FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
SERIAL LINK EXTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
ROLLING CODE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
VIN MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
STACK OVERFLOW FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
TRANSPONDER COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE . . . . . . . . . . . . .246
TRANSPONDER ID MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
TRANSPONDER RESPONSE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
VERIFICATION TESTS
VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
CONTROL MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
CONTROLS AND SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
A/C COMPRESSOR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
A/C PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . .257
BATTERY TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
BOOST PRESSURE SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
CAMSHAFT POSITION SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
CRANKSHAFT POSITION SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
EGR SOLENOID (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
v
TABLE OF CONTENTS - Continued
ENGINE CONTROL MODULE C1 (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
ENGINE CONTROL MODULE C2 (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
ENGINE COOLANT TEMP SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
ENGINE OIL PRESSURE SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
FUEL HEATER (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
FUEL INJECTOR NO. 1 (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
FUEL INJECTOR NO. 2 (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
FUEL INJECTOR NO. 3 (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
FUEL INJECTOR NO. 4 (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
FUEL PRESSURE SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
FUEL PRESSURE SOLENOID (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
GLOW PLUG RELAY (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
FUSES (IPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
A/C COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
ECM/PCM RELAY (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
FUEL HEATER RELAY (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
LIFT PUMP RELAY (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
LEFT SPEED CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
LIFT PUMP MOTOR (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
MASS AIR FLOW SENSOR (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
OVERHEAD CONSOLE (EXCEPT BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
RADIATOR FAN NO. 1 (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
RADIATOR FAN NO. 2 (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
RADIATOR FAN RELAY NO. 1 (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
RADIATOR FAN RELAY NO. 2 (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
RADIATOR FAN RELAY NO. 3 (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
RIGHT SPEED CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
VEHICLE SPEED SENSOR (MTX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
WATER IN FUEL SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
10.1 2003 RG 2.5L TURBO DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
10.2 2003 RG 2.5L TURBO DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
vi
1.0
INTRODUCTION
The procedures contained in this manual include
all specifications, instructions and graphics needed
to diagnose engine control module (ECM) and sen-
try key immobilizer system (SKIS) problems; they
are no start, diagnostic trouble code (DTC), 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 appropri-
ate service information for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added; carryover sys-
tems may be enhanced. IT IS RECOMMENDED
THAT YOU REVIEW THE ENTIRE MANUAL TO
BECOME FAMILIAR WITH ALL NEW AND
CHANGED DIAGNOSTIC PROCEDURES.
This manual will cover all the necessary require-
ments to begin a logical diagnostic path for each
problem. If there is a diagnostic trouble code (DTC)
detected, go to the trouble code test. If there are no
DTCs present, go to a no trouble code (*), symptom
based 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
2003 RG body vehicles equipped with the 2.5L
direct injection diesel engine.
1.2
SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the engine control module (ECM)
and sentry key immobilizer system (SKIS) is done
in six basic steps:
•
verification of complaint
•
verification of any related symptom
•
symptom analysis
•
problem isolation
•
repair of isolated problem
•
verification of proper operation
NOTE: All tests in this manual should be per-
formed with the engine at operating temperature,
unless specified within a particular test.
2.0
IDENTIFICATION OF
SYSTEM
The ECM is located in the left side of the engine
compartment between the left headlamp and the
integrated power module. The sentry key immobi-
lizer module (SKIM) is located below the steering
column behind the steering wheel.
3.0
SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1
GENERAL DESCRIPTION
The 2.5L direct injection diesel engine system is
equipped with the latest in technical advances. The
on-board diagnostics incorporated in the engine
control module and SKIM are intended to assist the
field technician in repairing vehicle problems by the
quickest means.
The engine system incorporates a common rail
fuel delivery design. This design utilizes electroni-
cally controlled solenoid valve type fuel injectors.
Each injector is controlled individually by the ECM.
Injector timing and fuel quantity are controlled by
the ECM based on inputs from the various sensors.
The precision control of the injectors by the ECM
helps to reduce the engine noise, odor and smoke.
3.2
FUNCTIONAL OPERATION
3.2.1
ECM ON-BOARD DIAGNOSTICS
The ECM has been programmed to monitor many
different circuits of the diesel fuel injection system.
This monitoring is called on-board diagnostics.
Certain criteria must be met for a trouble code to
be entered into the ECM memory. The criteria may
be a range of: engine rpm, engine temperature, time
or other input signals to the ECM. If all of the
criteria for monitoring a system or circuit are met,
and a problem is sensed, then a DTC will be stored
in the ECM memory.
It is possible that a DTC for a monitored circuit
may not be entered into the ECM memory, even
though a malfunction has occurred. This may hap-
pen when the monitoring criteria has not been met.
The ECM compares input signal voltages from
each input device with specifications (the estab-
lished high and low limits of the input range) that
are programmed into it for that device. If the input
voltage is not within the specifications and other
trouble code criteria are met, a DTC will be stored
in the ECM memory.
1
GENERAL INFORMATION
3.2.2
ECM OPERATING MODES
As input signals to the ECM change, the ECM
adjusts its response to the output devices. For
example, the ECM must calculate a different fuel
quantity and fuel timing for engine idle condition
than it would for a wide open throttle condition.
There are several different modes of operation that
determine how the ECM responds to the various
input signals.
Ignition Switch On (Engine Off)
When the ignition switch is turned on, the ECM
activates the glow plug relay for a time period that
is determined by engine coolant temperature, atmo-
spheric temperature and battery voltage. The ECM
also activates the lift pump to prime the fuel sys-
tem.
Engine Start-up Mode
The ECM uses the engine temperature sensor
and the crankshaft position sensor (engine speed)
inputs to determine fuel injection quantity.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration
and wide open throttle modes are controlled based
on all of the sensor inputs to the ECM. The ECM
uses these sensor inputs to adjust fuel quantity and
fuel injector timing.
Overheat Protection Mode
If the engine temperature is above 106°C (223°F)
and vehicle speed is above 40 km/h (25 MPH) the
ECM will activate the high speed fan and will limit
fuel quantity for engine protection.
Limp-In Mode
If there is a fault detected with the accelerator
pedal position sensor, the ECM will set the engine
speed at 1100 RPM.
Overspeed Detection Mode
If the ECM detects engine RPM that exceeds
5200 RPM, the ECM will set a DTC in memory,
limit engine RPM to no more than 2500 RPM, and
illuminate the MIL until the DTC is cleared.
After-Run Mode
The ECM transfers RAM information to ROM
and performs an Input/Output state check.
3.2.3
MONITORED CIRCUITS
The ECM is able to monitor and identify most
driveability related trouble conditions. Some cir-
cuits 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 engine 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, a specific set of conditions must occur
and unless these conditions occur, a DTC will not
set.
3.2.4
SKIS OVERIVEW
The sentry key immobilizer system (SKIS) is
designed to prevent unauthorized vehicle opera-
tion. The system consists of a sentry key immobi-
lizer module (SKIM), ignition key(s) equipped with
a transponder chip and the ECM. When the ignition
switch is turned on, the SKIM interrogates the
ignition key. If the ignition key is Valid or Invalid,
the SKIM sends a PCI Bus message to the ECM
indicating ignition key status. Upon receiving this
message the ECM will terminate engine operation
or allow the engine to continue to operate.
3.2.5
SKIS ON-BOARD DIAGNOSTICS
The sentry key immobilizer module (SKIM) has
been programmed to transmit and monitor many
different coded messages as well as PCI Bus mes-
sages. This monitoring is called On-Board Diagnos-
tics. Certain criteria must be met for a DTC to be
entered into SKIM memory. The criteria may be a
range of; input voltage, PCI Bus message or coded
messages to the SKIM. If all of the criteria for
monitoring a circuit or function are met and a fault
is detected, a DTC will be stored in the SKIM
memory.
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 complete, 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 - an electronically stored value (identi-
fication number) that is unique to each SKIS. The
secret key is stored in the SKIM, ECM and all
ignition key transponders.
Challenge - a random number that is generated by
the SKIM at each ignition key cycle.
The secret key and challenge are the two variables
used in the algorithm that produces the encrypted
response message. The transponder uses the crypto
algorithm to receive, decode and respond to the
message sent by SKIM. After responding to the coded
message, the transponder sends a transponder ID
2
GENERAL INFORMATION
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