2004 Chrysler Sebring Dodge Stratus Factory Service Repair Manual

TABLE OF CONTENTS 1.0 INTRODUCTION .........................................................1 1.1 SYSTEM COVERAGE ...............................................1 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1 2.0 IDENTIFICATION OF SYSTEM .............................................1 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................2 3.1 GENERAL DESCRIPTION ............................................2 3.2 FUNCTIONAL OPERATION ...........................................2 3.2.1 FUEL CONTROL ..........................................2 3.2.2 ON-BOARD DIAGNOSTICS ...................................2 3.2.3 OTHER CONTROLS .........................................5 3.2.4 PCM OPERATING MODES ..................................10 3.2.5 NON-MONITORED CIRCUITS ................................10 3.2.6 SKIS OVERVIEW ..........................................10 3.2.7 SKIM ON-BOARD DIAGNOSTICS .............................10 3.2.8 SKIS OPERATION..........................................10 3.2.9 PROGRAMMING THE POWERTRAIN CONTROL MODULE ........11 3.2.10 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE .....12 3.2.11 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE.....................................12 3.3 DIAGNOSTIC TROUBLE CODES .....................................12 3.3.1 HARD CODE ..............................................12 3.3.2 INTERMITTENT CODE ......................................13 3.3.3 STARTS SINCE SET COUNTER ..............................13 3.3.4 DISTANCE SINCE MI SET ...................................13 3.4 USING THE DRBIIIT ................................................13 3.5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN .....................13 3.5.1 DRBIIIT DOES NOT POWER UP..............................14 3.5.2 DISPLAY IS NOT VISIBLE ...................................14 4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................14 4.1 DISCLAIMERS.....................................................14 4.2 SAFETY ..........................................................14 4.2.1 TECHNICIAN SAFETY INFORMATION .........................14 4.2.2 VEHICLE PREPARATION FOR TESTING.......................14 4.2.3 SERVICING SUB ASSEMBLIES ..............................14 4.2.4 DRBIIIT SAFETY INFORMATION .............................14 4.3 WARNINGS AND CAUTIONS ........................................15 4.3.1 ROAD TEST WARNINGS ....................................15 4.3.2 VEHICLE DAMAGE CAUTIONS ..............................15 5.0 REQUIRED TOOLS AND EQUIPMENT .....................................15 6.0 GLOSSARY OF TERMS..................................................16 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................17 COMMUNICATION *NO RESPONSE FROM PCM (PCI BUS) - NGC ..............................18 *NO RESPONSE FROM PCM (PCI BUS) - SBEC .............................20 i

TABLE OF CONTENTS - Continued *NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC ........................22 *NO RESPONSE FROM PCM (SCI ONLY) - SBEC ............................25 *NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE ................28 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE - EATX ...........30 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE - NGC ...........33 *PCI BUS COMMUNICATION FAILURE .....................................36 DRIVEABILITY - GAS INTERMITTENT CONDITION ..............................................39 P0071 - AMBIENT TEMP SENSOR PERFORMANCE ..........................40 P0106-BAROMETRIC PRESSURE OUT OF RANGE ..........................42 P0107-MAP SENSOR VOLTAGE TOO LOW .................................45 P0108-MAP SENSOR VOLTAGE TOO HIGH .................................48 P0111-INTAKE AIR TEMP SENSOR PERFORMANCE .........................50 P0117-ECT SENSOR VOLTAGE TOO LOW ..................................52 P0118-ECT SENSOR VOLTAGE TOO HIGH .................................54 P0121-TPS VOLTAGE DOES NOT AGREE WITH MAP ........................56 P0122-THROTTLE POSITION SENSOR VOLTAGE LOW .......................60 P0123-THROTTLE POSITION SENSOR VOLTAGE HIGH ......................63 P0125-CLOSED LOOP TEMP NOT REACHED ...............................65 P0131-1/1 O2 SENSOR SHORTED TO GROUND .............................67 P0137-1/2 O2 SENSOR SHORTED TO GROUND .............................67 P0151-2/1 O2 SENSOR SHORTED TO GROUND .............................67 P0157-2/2 O2 SENSOR SHORTED TO GROUND .............................67 P0132-1/1 O2 SENSOR SHORTED TO VOLTAGE ............................70 P0138-1/2 O2 SENSOR SHORTED TO VOLTAGE ............................70 P0152-2/1 O2 SENSOR SHORTED TO VOLTAGE ............................70 P0158-2/2 O2 SENSOR SHORTED TO VOLTAGE ............................70 P0133-1/1 O2 SENSOR SLOW RESPONSE .................................73 P0139-1/2 O2 SENSOR SLOW RESPONSE .................................73 P0153-2/1 O2 SENSOR SLOW RESPONSE .................................73 P0159-2/2 O2 SENSOR SLOW RESPONSE .................................73 P0134-1/1 O2 SENSOR STAYS AT CENTER .................................75 P0140-1/2 O2 SENSOR STAYS AT CENTER .................................75 P0154-2/1 02 SENSOR STAYS AT CENTER .................................75 P0160-2/2 O2 SENSOR STAYS AT CENTER .................................75 P0135-1/1 O2 SENSOR HEATER FAILURE (6 CYLINDER) .....................78 P0141-1/2 O2 SENSOR HEATER FAILURE ..................................78 P0155-2/1 O2 SENSOR HEATER FAILURE ..................................78 P0161-2/2 O2 SENSOR HEATER FAILURE ..................................78 P0171-1/1 FUEL SYSTEM LEAN ...........................................81 P0174-2/1 FUEL SYSTEM LEAN ...........................................81 P0172-1/1 FUEL SYSTEM RICH ...........................................86 P0175-2/1 FUEL SYSTEM RICH ...........................................86 P0201-INJECTOR #1 CONTROL CIRCUIT 2.7L...............................91 P0202-INJECTOR #2 CONTROL CIRCUIT 2.7L...............................91 P0203-INJECTOR #3 CONTROL CIRCUIT 2.7L...............................91 P0204-INJECTOR #4 CONTROL CIRCUIT 2.7L...............................91 P0205-INJECTOR #5 CONTROL CIRCUIT 2.7L...............................91 P0206-INJECTOR #6 CONTROL CIRCUIT 2.7L...............................91 P0300-MULTIPLE CYLINDER MIS-FIRE .....................................95 P0301-CYLINDER #1 MISFIRE ............................................95 P0302-CYLINDER #2 MISFIRE ............................................95 ii

TABLE OF CONTENTS - Continued P0303-CYLINDER #3 MISFIRE ............................................95 P0304-CYLINDER #4 MISFIRE ............................................95 P0305-CYLINDER #5 MISFIRE ............................................95 P0306-CYLINDER #6 MISFIRE ............................................95 P0320-NO CRANK REFERENCE SIGNAL AT PCM ...........................102 P0325-KNOCK SENSOR #1 CIRCUIT .....................................107 P0340-NO CAM SIGNAL AT PCM .........................................110 P0351-IGNITION COIL #1 PRIMARY CIRCUIT 2.7L ..........................115 P0352-IGNITION COIL #2 PRIMARY CIRCUIT 2.7L ..........................115 P0353-IGNITION COIL #3 PRIMARY CIRCUIT 2.7L ..........................115 P0354-IGNITION COIL #4 PRIMARY CIRCUIT 2.7L ..........................115 P0355-IGNITION COIL #5 PRIMARY CIRCUIT 2.7L ..........................115 P0356-IGNITION COIL #6 PRIMARY CIRCUIT 2.7L ..........................115 P0401 - EGR SYSTEM FAILURE (2.7L) ....................................119 P0403 - EGR SOLENOID CIRCUIT ........................................123 P0404 - EGR POSITION SENSOR RATIONALITY ............................126 P0405 - EGR POSITION SENSOR VOLTS TOO LOW ........................129 P0406 - EGR POSITION SENSOR VOLTS TOO HIGH ........................132 P0420-1/1 CATALYTIC CONVERTER EFFICIENCY...........................135 P0432-2/1 CATALYTIC CONVERTER EFFICIENCY...........................135 P0441-EVAP PURGE FLOW MONITOR ....................................137 P0442-EVAP LEAK MONITOR MEDIUM LEAK DETECTED ....................139 P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED .....................139 P0456 - EVAP LEAK MONITOR LEAK DETECTED ...........................139 P0443-EVAP PURGE SOLENOID CIRCUIT .................................143 P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES........................146 P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW.......................148 P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH ......................148 P0500-NO VEHICLE SPEED SIGNAL (EATX TRANSMISSION) .................150 P0500-NO VEHICLE SPEED SIGNAL (MTX TRANSMISSION)..................152 P0505-IDLE AIR CONTROL MOTOR CIRCUITS .............................154 P0600-PCM FAILURE SPI COMMUNICATIONS..............................157 P0601-PCM INTERNAL CONTROLLER FAILURE ............................157 P0622-GENERATOR FIELD NOT SWITCHING PROPERLY ....................158 P0645-A/C CLUTCH RELAY CKT .........................................160 P0700-EATX CONTROLLER DTC PRESENT................................161 P0703-BRAKE SWITCH SENSE CIRCUIT ..................................162 P1192-INLET AIR TEMP SENSOR VOLTAGE LOW ...........................164 P1193-INLET AIR TEMP SENSOR VOLTAGE HIGH ..........................166 P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR ................168 P1196-2/1 O2 SENSOR SLOW DURING CATALYST MONITOR ................168 P1281-ENGINE IS COLD TOO LONG......................................170 P1282-FUEL PUMP RELAY CONTROL CIRCUIT.............................171 P1294-TARGET IDLE NOT REACHED .....................................173 P1297-NO CHANGE IN MAP FROM START TO RUN .........................176 P1299-VACUUM LEAK FOUND (IAC FULLY SEATED) ........................179 P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT.......................181 P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM .........................183 P1391-INTERMITTENT LOSS OF CMP OR CKP.............................185 P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT .........................189 P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND ......................191 P1489-HIGH SPEED FAN CONTROL RELAY CIRCUIT .......................194 P1490-LOW SPEED FAN CONTROL RELAY CIRCUIT ........................196 iii

TABLE OF CONTENTS - Continued P1492-AMBIENT/BATT TEMP SEN VOLTS TOO HIGH ........................198 P1493-AMBIENT/BATT TEMP SEN VOLTS TOO LOW ........................200 P1494-LEAK DETECT PUMP SW OR MECHANICAL FAULT ...................202 P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT .......................204 P1496-5 VOLT SUPPLY, OUTPUTTOO LOW ...............................206 P1594-CHARGING SYSTEM VOLTAGE TOO HIGH ..........................209 P1595-SPEED CONTROL SOLENOID CIRCUITS ............................211 P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT....................211 P1597-SPEED CONTROL SWITCH ALWAYS LOW ...........................216 P1598-A/C PRESSURE SENSOR VOLTS TOO HIGH .........................218 P1599-A/C PRESSURE SENSOR VOLTS TOO LOW .........................221 P1602-PCM NOT PROGRAMMED ........................................224 P1682-CHARGING SYSTEM VOLTAGE TOO LOW ...........................225 P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM ...............228 P1686 NO SKIM BUS MESSAGE RECEIVED ...............................230 P1687-NO CLUSTER BUS MESSAGE .....................................232 P1695-NO CCD/J1850 MESSAGE FROM BODY CONTROL MODULE ...........233 P1696-PCM FAILURE EEPROM WRITE DENIED ............................235 P1697-PCM FAILURE SRI MILE NOT STORED .............................235 P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE ...............237 P1899-P/N SWITCH STUCK IN PARK OR IN GEAR ..........................238 *CHECKING PCM POWER AND GROUND CIRCUITS ........................240 *CHECKING THE EVAP SYSTEM .........................................241 DRIVEABILITY - NGC INTERMITTENT CONDITION .............................................243 P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT ..................244 P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW ............................248 P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW ............................248 P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH ............................250 P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH ............................250 P0068-MANIFOLD PRESSURE/THROTTLE POSITION CORRELATION..........253 P0071-AMBIENT TEMP SENSOR PERFORMANCE ..........................259 P0072-AMBIENT TEMP SENSOR LOW ....................................262 P0073-AMBIENT TEMP SENSOR HIGH ....................................264 P0107-MAP SENSOR LOW ..............................................266 P0108-MAP SENSOR HIGH..............................................269 P0111-INTAKEAIR TEMPERATURE SENSOR PERFORMANCE ................272 P0112-INTAKE AIR TEMPERATURE SENSOR LOW ..........................275 P0113-INTAKE AIR TEMPERATURE SENSOR HIGH .........................277 P0116-ENGINE COOLANT TEMPERATURE PERFORMANCE..................279 P0117-ENGINE COOLANT TEMPERATURE SENSOR LOW ...................282 P0118-ENGINE COOLANT TEMPERATURE SENSOR HIGH ...................284 P0122-THROTTLE POSITION SENSOR #1 LOW ............................286 P0123-THROTTLE POSITION SENSOR #1 HIGH ............................289 P0125-INSUFFICIENT COOLANT TEMP FOR CLOSED-LOOP FUEL CONTROL . .292 P0128-THERMOSTAT RATIONALITY ......................................294 P0129-BAROMETRIC PRESSURE OUT-OF-RANGE LOW .....................299 P0131-O2 SENSOR 1/1 VOLTAGE LOW ...................................302 P0137-O2 SENSOR 1/2 VOLTAGE LOW ...................................302 P0132-O2 SENSOR 1/1 VOLTAGE HIGH ...................................305 P0138-O2 SENSOR 1/2 VOLTAGE HIGH ...................................305 P0133-O2 SENSOR 1/1 SLOW RESPONSE ................................308 iv

TABLE OF CONTENTS - Continued P0139-O2 SENSOR 1/2 SLOW RESPONSE ................................308 P0135-O2 SENSOR 1/1 HEATER PERFORMANCE ..........................310 P0141-O2 SENSOR 1/2 HEATER PERFROMANCE ..........................310 P0171-FUEL SYSTEM 1/1 LEAN ..........................................313 P0172-FUEL SYSTEM 1/1 RICH ..........................................318 P0201-FUEL INJECTOR #1 ..............................................322 P0202-FUEL INJECTOR #2 ..............................................322 P0203-FUEL INJECTOR #3 ..............................................322 P0204-FUEL INJECTOR #4 ..............................................322 P0205-FUEL INJECTOR #5 ..............................................322 P0206-FUEL INJECTOR #6 ..............................................322 P0300-MULTIPLE CYLINDER MISFIRE ....................................325 P0301-CYLINDER #1 MISFIRE ...........................................325 P0302-CYLINDER #2 MISFIRE ...........................................325 P0303-CYLINDER #3 MISFIRE ...........................................325 P0304-CYLINDER #4 MISFIRE ...........................................325 P0305-CYLINDER #5 MISFIRE ...........................................325 P0306-CYLINDER #6 MISFIRE ...........................................325 P0315-NO CRANK SENSOR LEARNED ....................................333 P0325-KNOCK SENSOR #1 CIRCUIT .....................................335 P0335-CRANKSHAFT POSITION SENSOR CIRCUIT .........................338 P0339-CRANKSHAFT POSITION SENSOR INTERMITTENT ...................343 P0340-CAMSHAFT POSITION SENSOR CIRCUIT ...........................347 P0344-CAMSHAFT POSITION SENSOR INTERMITTENT .....................352 P0401 - EGR SYSTEM PERFORMANCE ...................................356 P0403 - EGR CONTROL CIRCUIT ........................................359 P0404 - EGR POSITION SENSOR PERFORMANCE .........................362 P0405 - EGR POSITION SENSOR LOW ...................................366 P0406 - EGR POSITION SENSOR HIGH ...................................369 P0410-AIR INJECTION O2 SENSOR MONITOR .............................372 P0418-AIR PUMP RELAY CIRCUIT........................................375 P0420-CATALYTIC 1/1 EFFICIENCY .......................................377 P0432-CATALYTIC 2/1 EFFICIENCY .......................................377 P0440-GENERAL EVAP SYSTEM FAILURE.................................379 P0441-EVAP PURGE SYSTEM PERFORMANCE ............................384 P0442-EVAP SYSTEM MEDIUM LEAK .....................................386 P0455-EVAP SYSTEM LARGE LEAK ......................................386 P0443-EVAP PURGE SOLENOID CIRCUIT .................................391 P0452-NVLD PRESSURE SWITCH SENSE CIRCUIT LOW ....................394 P0453-NVLD PRESSURE SWITCH SENSE CIRCUIT HIGH....................397 P0456-EVAP SYSTEM SMALL LEAK ......................................399 P0461-FUEL LEVEL SENSOR #1 PERFORMANCE ..........................401 P0462-FUEL LEVEL SENSOR #1 LOW ....................................403 P0463-FUEL LEVEL SENSOR #1 HIGH ....................................403 P0480-LOW SPEED FAN CONTROL RELAY CIRCUIT ........................404 P0481-HIGH SPEED FAN CONTROL RELAY CIRCUIT .......................406 P0491-AIR INJECTION SYSTEM PERFORMANCE ...........................408 P2431-MAF SENSOR PERFORMANCE ....................................408 P0498-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW ..............413 P0499-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH .............414 P0501-VEHICLE SPEED SENSOR #1 PERFORMANCE (AUTO TRANS) .........416 P0501-VEHICLE SPEED SENSOR #1 PERFORMANCE (MANUAL TRANS) ......417 P0506-IDLE SPEED LOW PERFORMANCE ................................419 v

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2004 Chrysler Sebring Dodge Stratus Factory Service Repair Manual

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