Chrysler PT Cruiser. Manual - part 227

TABLE OF CONTENTS - Continued

P0572-BRAKE SWITCH #1 CIRCUIT LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440
P0573-BRAKE SWITCH #1 CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442
P0580-SPEED CONTROL SWITCH #1 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .444
P0581-SPEED CONTROL SWITCH #1 HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446
P0582-SPEED CONTROL VACUUM SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . .448
P0586-SPEED CONTROL VENT SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . .451
P0594-SPEED CONTROL SERVO POWER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . .454
P0600-SERIAL COMMUNICATION LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457
P0601-INTERNAL MEMORY CHECKSUM INVALID. . . . . . . . . . . . . . . . . . . . . . . . . . .457
P0622-GENERATOR FIELD CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .458
P0627-FUEL PUMP RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
P0630-VIN NOT PROGRAMMED IN PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462
P0632-ODOMETER NOT PROGRAMMED IN PCM . . . . . . . . . . . . . . . . . . . . . . . . . . .463
P0633-SKIM KEY NOT PROGRAMMED IN PCM. . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
P0645-A/C CLUTCH RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465
P0685-ASD RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
P0688-ASD RELAY SENSE CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469
P0700-TRANSMISSION CONTROL SYSTEM/READ TRANSMISSION DTCS
ON THE DRBIII

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472

P0850-PARK/NEUTRAL SWITCH PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .473
P1105-TIP SENSOR SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474
P1115-GENERAL TEMP SENSOR PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .476
P1187-THOTTLE INLET PRESSURE/MAP CORRELATION . . . . . . . . . . . . . . . . . . . .480
P1189-TIP SENSOR CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485
P1190-TIP SENSOR CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .488
P1593-SPEED CONTROL SWITCH STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491
P1603-PCM INTERNAL DUAL-PORT RAM COMMUNICATION . . . . . . . . . . . . . . . . .494
P1604-PCM INTERNAL DUAL-PORT RAM READ/WRITE INTEGRITY FAILURE . . .494
P1607-PCM INTERNAL SHUTDOWN TIMER RATIONALITY . . . . . . . . . . . . . . . . . . .494
P1696-EEPROM MEMORY WRITE DENIED/INVALID . . . . . . . . . . . . . . . . . . . . . . . . .495
P1697-EMR (SRI) MILEAGE NOT STORED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495
P1854-TIP BARO OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497
P2074-MANIFOLD PRESSURE/THROTTLE POSITION CORRELATION - HIGH
FLOW/VACUUM LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
P2096-DOWN STREAM FUEL SYSTEM 1/2 LEAN . . . . . . . . . . . . . . . . . . . . . . . . . . .507
P2097-DOWN STREAM FUEL SYSTEM 1/2 RICH . . . . . . . . . . . . . . . . . . . . . . . . . . .507
P2302-IGNITION COIL #1 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION . . .510
P2305-IGNITION COIL #2 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION . . .510
P2503-CHARGING SYSTEM VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513
U0101-NO TRANSMISSION BUS MESSAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516
U0155-NO CLUSTER BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518
U0168-NO SKIM BUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .519
U110C-NO FUEL LEVEL BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521
*CHECKING PCM POWER AND GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . .523
*CHECKING RADIATOR FAN RELAY OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .524
*CHECKING THE A/C RELAY OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .526

SENTRY KEY IMMOBILIZER
ANTENNA FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528
COP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528
EEPROM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528
INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528
RAM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528

TABLE OF CONTENTS - Continued

SERIAL LINK INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528
STACK OVERFLOW FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528
PCM STATUS FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .530
SERIAL LINK EXTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .530
ROLLING CODE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532
VIN MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532
TRANSPONDER COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE . . . . . . . . . . . . .534
TRANSPONDER ID MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
TRANSPONDER RESPONSE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534

STARTING
*CHECKING FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537
*CHECKING FUEL PRESSURE LEAK DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .540
*CHECKING HARD START (FUEL DELIVERY SYSTEM) . . . . . . . . . . . . . . . . . . . . . .541
*ENGINE CRANKS DOES NOT START - 1.6L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543
*ENGINE CRANKS DOES NOT START - 2.0L/2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . .550
*NO CRANK CONDITION 1.6L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .558
*NO CRANK CONDITION 2.0L/2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562
*NO RESPONSE FROM PCM WITH A NO START CONDITION . . . . . . . . . . . . . . . .565
*START AND STALL CONDITION 1.6L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .566
*START AND STALL CONDITION 2.0L/2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .569

VERIFICATION TESTS
VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572

8.0

COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .581

8.1

POWERTRAIN AND SKIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .581

8.2

CONTROL AND SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .581

8.3

DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .583

8.4

SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .583

8.5

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .586

8.6

RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .586

8.7

SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587

9.0

CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589

A/C COMPRESSOR CLUTCH (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .589
A/C LOW PRESSURE SWITCH - DK. GREEN 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .589
A/C PRESSURE TRANSDUCER - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589
ACCELERATOR PEDAL POSITION SENSOR (1.6L/DIESEL) - 10 WAY . . . . . . . . . .589
AMBIENT TEMPERATURE SENSOR (EXCEPT 2.4L BASE) - BLACK 2 WAY . . . . .590
AMBIENT TEMPERATURE SENSOR (NGC) - BLACK 2 WAY . . . . . . . . . . . . . . . . . .590
BRAKE LAMP SWITCH (GAS) - GRAY 6 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .590
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . .590
CAMSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . .591
CLUTCH PEDAL POSITION SWITCH (UP) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . .591
CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . .591
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591
EGR SOLENOID (DIESEL) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592
ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY . . . . . . .592
ENGINE COOLANT TEMPERATURE SENSOR (GAS) - BLACK 2 WAY . . . . . . . . . .592
ENGINE OIL PRESSURE SWITCH - LT. GREEN 2 WAY . . . . . . . . . . . . . . . . . . . . . .592

vii

TABLE OF CONTENTS - Continued

EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .593
FUEL INJECTOR NO. 1 (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
FUEL INJECTOR NO. 2 (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
FUEL INJECTOR NO. 3 (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
FUEL INJECTOR NO. 4 (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .594
FUEL PUMP MODULE - LT. GRAY 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .594
GENERATOR (2.4L TURBO) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .594
GENERATOR (GAS EXCEPT 2.4L TURBO) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . .594
IDLE AIR CONTROL MOTOR (2.4L) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . .595
IGNITION COIL (GAS) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .595
INLET AIR TEMPERATURE SENSOR (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . .595
KNOCK SENSOR (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .595
MANIFOLD ABSOLUTE PRESSURE SENSOR (GAS) - BLACK 3 WAY . . . . . . . . . .596
NATURAL VACUUM LEAK DETECTION ASSEMBLY (EXCEPT EXPORT) -
BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .596
OXYGEN SENSOR 1/1 UPSTREAM (GAS) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . .596
OXYGEN SENSOR 1/2 DOWNSTREAM (GAS) - BLACK 4 WAY . . . . . . . . . . . . . . . .596
A/C COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
AUTO SHUT DOWN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
HIGH SPEED RADIATOR FAN RELAY (2.4L TURBO). . . . . . . . . . . . . . . . . . . . . . . . .598
HIGH SPEED RADIATOR FAN RELAY (EXCEPT 2.4L TURBO) . . . . . . . . . . . . . . . . .598
LOW SPEED RADIATOR FAN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .599
POWERTRAIN CONTROL MODULE (1.6L) - BLACK 90 WAY . . . . . . . . . . . . . . . . . .600
POWERTRAIN CONTROL MODULE C1 (NGC) - BLACK/BLACK 38 WAY . . . . . . . .601
POWERTRAIN CONTROL MODULE C2 (NGC) - BLACK/ORANGE 38 WAY . . . . . .602
POWERTRAIN CONTROL MODULE C3 (NGC) - BLACK/NATURAL 38 WAY . . . . . .603
POWERTRAIN CONTROL MODULE C4 (NGC) - BLACK/GREEN 38 WAY. . . . . . . .604
RADIATOR FAN MOTOR (2.4L TURBO) - DK. GRAY 4 WAY . . . . . . . . . . . . . . . . . . .605
RADIATOR FAN MOTOR (EXCEPT 2.4L TURBO) - BLACK 3 WAY . . . . . . . . . . . . . .605
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . .605
SPEED CONTROL SERVO (2.4L) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .605
SPEED CONTROL SWITCH - YELLOW 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .606
SURGE SOLENOID (2.4L TURBO) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .606
THROTTLE INLET PRESSURE SENSOR (2.4L TURBO) - NATURAL 3 WAY . . . . . .606
THROTTLE INLET PRESSURE SOLENOID (2.4L TURBO) - BLACK 2 WAY . . . . . .606
THROTTLE POSITION SENSOR (2.4L) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . .607
VEHICLE SPEED SENSOR (GAS MTX) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . .607
WASTEGATE SOLENOID (2.4L TURBO) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .607

10.0

SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .609

10.1 PT 1.6L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .609
10.2 PT 2.0L AND 2.4L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .611

11.0

CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615

viii

IMPORTANT (NGC)

The

2.0/2.4

equipped

with

the

Powertrain Control Module and Transmission
Control Module combined in a single control
module. This module is the Next Generation
Controller (NGC) for DaimlerChrysler and will
be referred to as the Powertrain Control
Module (PCM).
The PCM has four color coded connectors C1
through C4, (C1 - BLK, C2 - ORANGE, C3 -
WHITE, C4 - GREEN), with each connector
containing 38 pins.
Two tools are required to diagnose and repair
the PCM terminals and harness connectors:

1. Miller #3638 Terminal Removal Pick must

used

release

the

connector

terminals

harness

and

connector

damage will occur.

2. Miller #8815 Pinout Box must be used to

probe the PCM terminals or terminal
damage will occur.

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

displays a No Response condition, you must
diagnose this first before proceeding.

2. Read DTC’s (diagnostic trouble codes) with the

DRBIII

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

2005 PT vehicle equipped with the 1.6L, 2.0L/2.4L
and the 2.4L turbo engines.

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

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.

GENERAL INFORMATION

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