Chrysler Town, Dodge Caravan. Manual — part 548
TABLE OF CONTENTS - Continued
SENTRY KEY IMMOBILIZER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539
SPEED CONTROL SERVO (GAS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539
THROTTLE POSITION SENSOR (GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539
TRANSMISSION RANGE SENSOR (EATX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539
SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541
10.1 2003 RS 2.4L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541
10.2 2003 RS 3.3L/3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543
CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .545
viii
IMPORTANT
New for the 2003 RS equipped with the 2.4L is
a combined Powertrain Control Module and
Transmission Control Module in a single
control module. This new module is the Next
Generation
Controller
(NGC)
for
DaimlerChrysler and will be referred to as the
Powertrain Control Module (PCM).
New Diagnostics procedures and New DTC
numbers are some of the changes you will
see which reflect the new combined module
technology. The PCM will have four color
coded connectors C1 through C4, (C1-BLK,
C2-ORANGE, C3-WHITE, C4-GREEN), each
PCM connector will have 38 pins each. Two
new
tools
are
introduced
to
help
in
diagnosing and repairing the new PCM
terminals and harness connectors. The Miller
#3638 terminal removal pick is introduced,
you must use the Miller #3638 tool to release
the connector terminals or harness and
connector damage will occur. Also, the Miller
#8815 Pinout Box is introduced, you must
use the Miller #8815 tool to probe the PCM
terminals or terminal damage will occur.
There is also a new Verification test and
module replacement procedure for the new
PCM.
1.0
INTRODUCTION
The procedures contained in this manual include
specifications, instructions, and graphics needed to
diagnose the PCM Powertrain System. The diag-
nostics in this manual are based on the failure
condition or symptom being present at time of
diagnosis.
Please follow the recommendations below when
choosing your diagnostic path.
1. First make sure the DRBIII
t is communicating
with the appropriate modules; ie., if the DRBIII
t
displays a No Response condition, you must
diagnose this first before proceeding.
2. Read DTC’s (diagnostic trouble codes) with the
DRBIII
t.
3. If no DTC’s are present, identify the customer
complaint.
4. Once the DTC or customer complaint is identi-
fied, locate the matching test in the Table of
Contents and begin to diagnose the symptom.
All component location views are in Section 8.0.
All connector pinouts are in Section 9.0. All system
schematics are in Section 10.0.
An * placed before the symptom description indi-
cates a customer complaint.
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. READ THIS DIAGNOSTIC
INFORMATION BEFORE TRYING TO DIAG-
NOSE A VEHICLE CODE. It is recommended that
you review the entire diagnostic information to
become familiar with all new and changed diagnos-
tic procedures.
If you have any comments or recommendations
after reviewing the diagnostic information, 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 the
2003 RS vehicle equipped with the following en-
gines and powertrain control modules:
•
2.4L (NGC)
•
3.3L/3.8L (SBEC)
1.2
SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the powertrain control module
(PCM) is done in six basic steps:
•
verification of complaint
•
verification of any related symptoms
•
symptom analysis
•
problem isolation
•
repair of isolated problem
•
verification of proper operation
2.0
IDENTIFICATION OF
SYSTEM
The Powertrain Control Module (PCM) monitors
and controls:
•
Fuel System
•
Idle Air Control System
•
Ignition System
•
Charging System
•
Speed Control System
•
Cooling system
1
GENERAL INFORMATION
3.0
SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1
GENERAL DESCRIPTION
These Sequential Fuel Injection (SFI) engine sys-
tems have the latest in technical advances. The
OBDII/Euro Stage III OBD diagnostics incorpo-
rated with the Powertrain Control Module (PCM)
are intended to assist the field technician in repair-
ing vehicle problems by the quickest means.
3.2
FUNCTIONAL OPERATION
3.2.1
FUEL CONTROL
The PCM controls the air/fuel ratio of the engine
by varying fuel injector on time. Mass air flow is
calculated using the speed density method using
enigne speed, manifold absolute pressure, and air
temperature change.
Different fuel calculation strategies are used de-
pending on the operational state of the engine.
During crank mode, a longer pulse width fuel pulse
is delivered followed by fuel pulses determined by a
crank time strategy. Cold engine operation is deter-
mined via an open loop strategy until the O2
sensors have reached operating temperature. At
this point, the strategy enters a closed loop mode
where fuel requirements are based upon the state of
the O2 sensors, engine speed, MAP, throttle posi-
tion, air temperature, battery voltage, and coolant
temperature.
3.2.2
ON-BOARD DIAGNOSTICS
The PCM has been programmed to monitor many
different circuits of the fuel injection system. This
monitoring is called on-board diagnosis.
Certain criteria, or arming conditions, must be
met for a trouble code to be entered into the PCM
memory. The criteria may be a range of: engine rpm,
engine temperature, and/or input voltage to the
PCM. If a problem is sensed with a monitored
circuit, and all of the criteria or arming conditions
are met, then a trouble code will be stored in the
PCM.
It is possible that a trouble code for a monitored
circuit may not be entered into the PCM memory
even though a malfunction has occurred. This may
happen because one of the trouble code criteria have
not been met.
The PCM compares input signal voltages from
each input device with specifications (the estab-
lished high and low limits of the range) that are
programmed into it for that device. If the input
voltage is not within specifications and other trou-
ble code criteria are met, a trouble code will be
stored in the PCM memory.
The On Board Diagnostics have evolved to the
second Generation of Diagnostics referred to as
OBDII/Euro Stage III OBD. These OBDII/Euro
Stage III OBD Diagnostics control the functions
necessary to meet the requirements of California
OBDII, Federal OBD regulation and European reg-
ulation. These requirements specify the inclusion of
a Malfunction Indicator Light (MIL) located on the
instrument panel. The purpose of the MIL is to
inform the vehicle operator in the event of a mal-
function of any emission system or component.
MIL Lamp Strategy
I/M Readiness OK to test = Key On Engine OFF
– MIL Lamp will remain on until the vehicle is
started or Ignition is turned off.
I/M not ready for testing = Key On Engine OFF
– MIL Lamp on solid for (15) seconds then MIL
Lamp will flash on/off for (5) seconds then it will
remain on until the vehicle is started or the Ignition
is turned off.
2
GENERAL INFORMATION
OBD II/EURO STAGE III OBD MONITOR INFORMATION
Comprehensive
Major Monitors
Major Monitors
Components
Non Fuel Control
Fuel Control
Monitor
& Non Misfire
& Misfire
Run constantly
Run Once Per Trip
Run Constantly
Includes All Engine Hardware
Monitors Entire Emission
Monitors Entire System
- Sensors, Switches,
System
Solenoids, etc.
One Trip Faults - Turns On
Two Trip Faults - Turns On
Two Trip Faults - Turns On
The MIL and Sets DTC After
The MIL and Sets DTC After
The MIL and Sets DTC After
One Failure
Two Consecutive Failures
Two Consecutive Failures
Priority 3
Priority 1 or 3
Priority 2 or 4
All Checked For Continuity
Done Stop Testing = Yes
Fuel Control Monitor
Open
Monitors Fuel Control
Short To Ground
Oxygen Sensor Heater
System For:
Short To Voltage
Oxygen Sensor Response
Fuel System Lean
Fuel System Rich
Inputs Checked For
Requires 3 Consecutive
Rationality
Catalytic Converter
Fuel System Good Trips
To
Efficiency Except EWMA
Extinguish The MIL
Outputs Checked For
- up to 6 tests per trip
Functionality
and a one trip fault
EGR System
Misfire Monitor
Evaporative Emission
Monitors For Engine Misfire
System
at:
1000 RPM Counter
(Type B)
**200 RPM Counter
(Type A)
Requires 3 Consecutive
Requires 3 Consecutive
Requires 3 Consecutive
Global/Alternate Good Trips
Global Good Trips
Misfire Good Trips
to Extinguish the MIL*
to Extinguish the MIL*
To Extinguish the MIL
*40 Warm Up Cycles are required to erase
**Type A misfire is a two
DTC’s
after
the MIL has been extinguished.
trip failure. The MIL will
illuminate and blink at
the first failure.
3
GENERAL INFORMATION
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