DODGE SPRINTER 2002-2006 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 ......................1 3.1 AIRBAG SYSTEM ...................................................1 3.1.1 DRIVER AIRBAG............................................2 3.1.2 CLOCKSPRING.............................................3 3.1.3 PASSENGER AIRBAG .......................................3 3.1.4 SEAT BELT TENSIONERS ....................................3 3.1.5 SPECIAL TOOLS............................................3 3.1.6 DIAGNOSTIC TROUBLE CODES ..............................4 3.1.6.1 ACTIVE CODES ............................................4 3.1.6.2 STORED CODES ...........................................4 3.2 COMMUNICATION ..................................................4 3.2.1 COMMUNICATION K-LINES ..................................4 3.2.2 CAN BUS ..................................................5 3.3 HEATING & A/C SYSTEM ............................................5 3.3.1 AUTOMATIC TEMPERATURE CONTROL (ATC) ..................5 3.3.1.1 SYSTEM CONTROLS ........................................5 3.3.1.2 SYSTEM DIAGNOSTICS .....................................5 3.3.2 CABIN HEATER MODULE (CHM) & HEATER BOOSTER MODULE (HBM) .....................................................7 3.3.2.1 SYSTEM DESCRIPTION .....................................7 3.3.2.2 VENTING THE HEATER’S EXHAUST ...........................8 3.3.2.3 SYSTEM DIAGNOSTICS .....................................8 3.4 INSTRUMENT CLUSTER .............................................9 3.5 POWER DOOR LOCKS/RKE ..........................................9 3.5.1 CENTRAL LOCKING.........................................9 3.5.2 REMOTE KEYLESS ENTRY (RKE) .............................9 3.5.3 AUTO DOOR LOCKS .......................................10 3.5.4 ACCIDENT RESPONSE .....................................10 3.6 VEHICLE THEFT SECURITY SYSTEM (VTSS) ..........................10 3.7 USING THE DRBIIIT ................................................11 3.8 DRBIIIT ERROR MESSAGES.........................................11 3.9 DRBIIIT DOES NOT POWER UP (BLANK SCREEN) ......................11 3.10 DISPLAY IS NOT VISIBLE ...........................................11 4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................11 4.1 DISCLAIMERS .....................................................11 4.2 SAFETY ..........................................................11 4.2.1 TECHNICIAN SAFETY INFORMATION .........................11 4.2.2 VEHICLE PREPARATION FOR TESTING .......................12 4.2.3 SERVICING SUB-ASSEMBLIES ..............................12 4.2.4 DRBIIIT SAFETY INFORMATION .............................12 4.3 WARNINGS .......................................................12 4.3.1 VEHICLE DAMAGE WARNINGS ..............................12 4.3.2 ROAD TESTING A COMPLAINT VEHICLE ......................12 i

TABLE OF CONTENTS - Continued 5.0 REQUIRED TOOLS AND EQUIPMENT .....................................13 6.0 GLOSSARY OF TERMS..................................................13 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................15 AIRBAG AIRBAG WARNING INDICATOR - DRIVER HIGH .............................16 AIRBAG WARNING INDICATOR - DRIVER LOW..............................19 DRIVER SEAT BELT TENSIONER - INCORRECT FEEDBACK ..................22 DRIVER SQUIB 1 - INCORRECT FEEDBACK ................................22 INTERNAL 1 ...........................................................22 INTERNAL 2 ...........................................................22 INTERNAL 3 ...........................................................22 PASSENGER SEAT BELT TENSIONER - INCORRECT FEEDBACK ..............22 PASSENGER SQUIB 1 - INCORRECT FEEDBACK............................22 STORED ENERGY FIRING 1..............................................22 STORED ENERGY FIRING 2..............................................22 DRIVER SEAT BELT TENSIONER CIRCUIT OPEN ............................24 DRIVER SEAT BELT TENSIONER CIRCUIT SHORT ..........................26 DRIVER SEAT BELT TENSIONER SHORT TO BATTERY.......................28 DRIVER SEAT BELT TENSIONER SHORT TO GROUND .......................31 DRIVER SQUIB 1 CIRCUIT OPEN .........................................33 DRIVER SQUIB 1 CIRCUIT SHORT ........................................36 DRIVER SQUIB 1 SHORT TO BATTERY ....................................39 DRIVER SQUIB 1 SHORT TO GROUND ....................................42 LOSS OF IGNITION RUN - START .........................................45 PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN .......................47 PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT ......................49 PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY ..................51 PASSENGER SEAT BELT TENSIONER SHORT TO GROUND ..................54 PASSENGER SQUIB 1 CIRCUIT OPEN .....................................56 PASSENGER SQUIB 1 CIRCUIT SHORT ....................................59 PASSENGER SQUIB 1 SHORT TO BATTERY ................................62 PASSENGER SQUIB 1 SHORT TO GROUND ................................65 *AIRBAG WARNING INDICATOR FLASHING.................................68 CABIN HEATER A. HEATER PRE-TEST ...................................................69 CIRC PUMP CONTROL OPEN ............................................72 CIRC PUMP CONTROL SHORTED.........................................74 COMBUST FAN SHORTED ...............................................76 COMBUST FAN SPEED INCORRECT ......................................76 COMBUSTION FAN OPEN................................................76 CONTROL UNIT FAULTY .................................................77 DOSING PUMP OPEN ...................................................78 DOSING PUMP SHORTED ...............................................81 FAN STAGE 1 RELAY CONTROL OPEN ....................................83 FAN STAGE 1 RELAY CONTROL SHORTED.................................85 FLAME DETECT PRIOR TO COMBUST .....................................87 FLAME OUT ...........................................................88 NO START .............................................................88 FLAME SENSOR OPEN ..................................................91 ii

TABLE OF CONTENTS - Continued FLAME SENSOR SHORTED ..............................................91 GLOW PIN OPEN .......................................................91 GLOW PIN SHORTED ...................................................91 HEATER IN LOCKOUT MODE .............................................93 HEATER OVERHEATED..................................................93 SUCCESSIVE OVERHEATING ............................................93 OVER VOLTAGE ........................................................96 OVERHEATING SENSOR OPEN...........................................97 OVERHEATING SENSOR SHORTED .......................................97 TEMP SENSOR OPEN ...................................................98 TEMP SENSOR SHORTED ...............................................98 UNDER VOLTAGE ......................................................99 COMMUNICATION *NO RESPONSE FROM AIRBAG CONTROL MODULE .......................102 *NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL ..............104 *NO RESPONSE FROM CABIN HEATER MODULE ..........................106 *NO RESPONSE FROM CENTRAL TIMER MODULE .........................108 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE ...................110 *NO RESPONSE FROM ENGINE CONTROL MODULE .......................112 *NO RESPONSE FROM HEATER BOOSTER MODULE .......................114 *NO RESPONSE FROM INSTRUMENT CLUSTER ...........................116 *NO RESPONSE FROM RADIO ..........................................118 *NO RESPONSE FROM SECURITY SYSTEM MODULE ......................120 *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE .............122 *NO RESPONSE FROM SHIFTER ASSEMBLY ..............................124 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE ................126 HEATING & A/C A/C COMPRESSOR CONTROL HIGH OR OPEN (ACTIVE) ....................128 A/C COMPRESSOR CONTROL HIGH OR OPEN (STORED) ...................130 A/C COMPRESSOR CONTROL SHORTED LOW (STORED) ...................130 AIR OUTLET TEMP SENSOR HIGH OR OPEN (STORED) ....................130 AIR OUTLET TEMP SENSOR SHORTED LOW (STORED) ....................130 AUX FAN RELAY CONTROL HIGH OR OPEN (STORED) .....................130 AUX FAN RELAY CONTROL SHORTED LOW (STORED) .....................130 BLOWER STAGE 1 HIGH OR OPEN (STORED) .............................130 BLOWER STAGE 1 SHORTED LOW (STORED) .............................130 CABIN HEATER CONTROL HIGH OR OPEN (STORED) ......................130 CABIN HEATER CONTROL SHORTED LOW (STORED) ......................130 CIRC PUMP CONTROL HIGH OR OPEN (STORED) .........................130 CIRC PUMP CONTROL SHORTED LOW (STORED) .........................130 EVAP TEMP SENSOR HIGH OR OPEN (STORED) ..........................130 EVAP TEMP SENSOR SHORTED LOW (STORED) ..........................130 NO COMMUNICATION BUS (STORED) ....................................130 NO COMMUNICATION WITH ECM (STORED) ..............................130 NO COMMUNICATION WITH IC (STORED) .................................130 RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (STORED) ...............130 RECIRC AIR SOLENOID CONTROL SHORTED LOW (STORED) ...............130 REFRIG PRESS SENSOR HIGH OR OPEN (STORED) .......................130 REFRIG PRESS SENSOR SHORTED LOW (STORED) .......................130 WATER CYCLE VALVE CONTROLHIGH OR OPEN (STORED) ................130 WATER CYCLE VALVE CONTROLSHORTED LOW (STORED) ................130 iii

TABLE OF CONTENTS - Continued A/C COMPRESSOR CONTROL SHORTED LOW (ACTIVE) ....................132 AIR OUTLET TEMP SENSOR HIGH OR OPEN (ACTIVE) .....................134 AIR OUTLET TEMP SENSOR SHORTED LOW (ACTIVE) .....................136 ATC FUNCTION TEST COOL FAILURE ....................................138 ATC FUNCTION TEST FAILURE ..........................................138 ATC FUNCTION TEST HEAT FAILURE.....................................138 AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE) ......................140 AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE) ......................142 BLOWER STAGE 1 HIGH OR OPEN (ACTIVE) ..............................144 BLOWER STAGE 1 SHORTED LOW (ACTIVE) ..............................146 CABIN HEATER CONTROL HIGH OR OPEN (ACTIVE) .......................148 CABIN HEATER CONTROL SHORTED LOW (ACTIVE) .......................150 CIRC PUMP CONTROL HIGH OR OPEN (ACTIVE) ..........................152 CIRC PUMP CONTROL SHORTED LOW (ACTIVE) ..........................154 EVAP TEMP SENSOR HIGH OR OPEN (ACTIVE) ...........................156 EVAP TEMP SENSOR SHORTED LOW (ACTIVE) ...........................158 NO COMMUNICATION BUS (ACTIVE) .....................................160 NO COMMUNICATION WITH ECM (ACTIVE) ...............................163 NO COMMUNICATION WITH IC (ACTIVE) ..................................165 RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (ACTIVE) ................167 RECIRC AIR SOLENOID CONTROL SHORTED LOW (ACTIVE) ................169 REFRIG PRESS SENSOR HIGH OR OPEN (ACTIVE) ........................171 REFRIG PRESS SENSOR SHORTED LOW (ACTIVE) ........................173 WATER CYCLE VALVE CONTROLHIGH OR OPEN (ACTIVE) .................175 WATER CYCLE VALVE CONTROLSHORTED LOW (ACTIVE) .................177 INSTRUMENT CLUSTER AMBIENT TEMP SENSOR OPEN/SHORT TO BATTERY ......................179 AMBIENT TEMP SENSOR SHORT TO GROUND ............................181 FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY .........................182 FUEL LEVEL SENSOR SHORT TO GROUND ...............................184 INSTRUMENT CLUSTER INTERNAL FAILURE B1043 ........................185 INSTRUMENT CLUSTER INTERNAL FAILURE B1053 ........................186 INSTRUMENT CLUSTER OVERVOLTAGE ..................................187 NO CAN COMMUNICATION WITH ABS ....................................188 NO CAN COMMUNICATION WITH ECM ...................................190 NO CAN COMMUNICATION WITH TCM....................................192 PREGLOW INDICATOR LAMP FAILURE ...................................194 SRS INDICATOR LAMP FAILURE .........................................195 POWER DOOR LOCKS/RKE DRIVER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND ......196 PASSENGER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND .198 REPLACE CONTROL MODULE ..........................................200 RKE INTERFACE CIRCUIT SHORT TO GROUND - CTM ......................201 RKE INTERFACE CIRCUIT SHORT TO GROUND - SKREEM ..................203 RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - CTM .....................205 RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - SKREEM..................206 THE ACM HAS UNLOCKED THE DOORS ..................................208 UNKNOWN TROUBLE CODE UNKNOWN DTC TYPE 2 ......................209 *RKE INOPERATIVE ....................................................210 *RKE POOR RANGE ...................................................211 iv

TABLE OF CONTENTS - Continued VEHICLE THEFT/SECURITY DRIVER CYLINDER LOCK SWITCH CIRCUIT SHORT TO GROUND ............212 DRIVER CYLINDER UNLOCK SWITCH CIRCUIT SHORT TO GROUND .........214 FRONT DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND ................216 INTERNAL ERROR - SSM ...............................................218 TOWING INCLINATION SENSOR BEYOND LIMITS ..........................218 TOWING INCLINATION SENSOR VALUE IS INVALID.........................218 TOWING INCLINATION SENSOR VALUE IS MISSING ........................218 INTRUSION SENSOR 1 CIRCUIT OPEN/SHORT TO GROUND ................220 INTRUSION SENSOR 1 GROUND CIRCUIT OPEN ..........................222 INTRUSION SENSOR 2 CIRCUIT OPEN/SHORT TO GROUND ................223 INTRUSION SENSOR 2 GROUND CIRCUIT OPEN ..........................225 INTRUSION SENSOR 3 CIRCUIT OPEN/SHORT TO GROUND ................226 INTRUSION SENSOR 3 GROUND CIRCUIT OPEN ..........................228 REAR OR SLIDING DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND ......229 RKE INTERFACE CIRCUIT FAILURE - SSM ................................231 SECURITY SYSTEM INTERFACE FAILURE - SSM...........................233 SIREN CIRCUIT OPEN/SHORTED TO GROUND ............................235 SIREN INTERNAL FAILURE .............................................237 SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND ....................238 WINDSHIELD WIPER & WASHER CHECKING THE RAIN SENSOR/WIPER OPERATION ........................239 VERIFICATION TESTS VERIFICATION TESTS ..................................................244 8.0 COMPONENT LOCATIONS ..............................................249 8.1 AIRBAG SYSTEM .................................................249 8.2 AIRBAG CONTROL MODULE .......................................249 8.3 DRIVER AIRBAG SQUIB ...........................................249 8.4 CLOCKSPRING ..................................................250 8.5 SEAT BELT TENSIONER ...........................................250 8.6 HEATING & A/C...................................................250 8.6.1 AUTOMATIC TEMPERATURE CONTROL (ATC) SYSTEM COMPONENTS ...........................................250 8.6.2 CABIN HEATER & HEATER BOOSTER SYSTEM COMPONENTS .251 8.6.3 AUTO TEMP CONTROL, CABIN HEATER, & HEATER BOOSTER FUSES & RELAYS ........................................251 8.6.4 EVAP TEMP SENSOR & AIR OUTLET TEMP SENSOR ..........251 8.7 INSTRUMENT CLUSTER ...........................................252 8.7.1 AMBIENT TEMPERATURE SENSOR .........................252 8.8 POWER DOOR LOCKS/RKE ........................................252 8.8.1 CENTRAL TIMER MODULE .................................252 8.8.2 SENTRY KEY REMOTE ENTRY MODULE .....................253 8.8.3 DOOR LOCK MOTOR/AJAR SWITCH ........................253 8.8.4 CONTACT PLATES ........................................253 8.8.5 DOOR LOCK MOTOR/AJAR SWITCH CONNECTORS ...........254 v

DODGE SPRINTER 2002-2006 Service Repair Manual

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