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Powertrain Control Modules (PCM) - Electrical Diagnosis Chrysler Town & Country V

Testing & Diagnostics 7 illustrations ~3255 words

PCM VERIFICATION TEST

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for Grand Caravan.

SYSTEM WIRING DIAGRAMS for Town & Country.

Diagnostic Test

  1. VERIFICATION TESTS Select the verification test for the repair that has been completed: Speed Control repair Go to step 2 . Charging System repair Go to step 3 . No Start repair Go to step 4 . All other repairs Go to step 5 .
  2. SPEED CONTROL VERIFICATION TEST 1. Inspect the vehicle to verify that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. 2. With the scan tool, erase all diagnostic trouble codes (DTCs). 3. Road test the vehicle at a speed above 60 km/h (35 MPH). 4. Press the Cruise On/Off switch to turn the speed control on. 5. Move the speed control switch to the Set/Decel position. If the speed control does not engage, the repair is not complete, continue with step 12. 6. Move the speed control switch to the Resume/Accel position. If the vehicle speed does not increase by 3 km/h (2 MPH), the repair is not complete, continue with step 12. 7. Using caution, press and release the brake pedal. If the speed control does not disengage, the repair is not complete, continue with step 12. 8. With the vehicle speed at least 60 km/h (35 MPH), move the speed control switch to the Resume/Accel position. If the speed control does not resume at the previously set speed, the repair is not complete, continue with step 12. 9. Move the speed control switch to the Set/Decel position. If the vehicle does not decelerate, the repair is not complete, continue with step 12. 10. Hold the speed control switch in the Set/Decel position and release the switch with the vehicle speed above 60 km/h (35 MPH). If the vehicle speed does not adjust and set a new vehicle speed, the repair is not complete, continue with step 12. 11. With the speed control engaged, press the Cruise On/Off switch. If the speed control does not disengage, the repair is not complete, continue with step 12. 12. If the vehicle did not successfully perform all of the previous steps, check for Technical Service Bulletins (TSBs) that pertain to this speed control problem and then, if necessary, return to the Symptom List. 13. If the vehicle successfully performed all of the previous steps, the speed control system is now functioning as designed. The repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, refer to the appropriate diagnostic procedure. No Repair is complete.
  3. CHARGING SYSTEM VERIFICATION TEST 1. Inspect the vehicle to verify that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. 2. With the scan tool, erase all diagnostic trouble codes (DTCs). 3. Start the engine. 4. Raise the engine speed to 2000 RPM for at least 30 seconds. 5. Allow the engine to idle. 6. Turn the ignition off for 20 seconds. 7. Turn the ignition on. 8. With the scan tool, read PCM DTCs. 9. If this DTC has set again, or another DTC has set, look for any Technical Service Bulletins (TSBs) that may relate to this condition. Return to the Symptom List if necessary. 10. If the charging system is functioning correctly and there are no DTCs, the repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, refer to the appropriate diagnostic procedure. No Repair is complete.
  4. NO START VERIFICATION TEST NOTE: IMPORTANT! If the Powertrain Control Module or Sentry Key Immobilizer Module has been replaced, verify the programming procedure for the module has been performed in accordance with the Service Information. 1. Inspect the vehicle to verify that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. 2. Inspect the engine oil for contamination. If it is contaminated, the oil and the oil filter must be changed. 3. With the scan tool, erase all diagnostic trouble codes (DTCs). 4. Turn the ignition off for at least 10 seconds. 5. Attempt to start the engine. 6. If the engine will not start, refer to any Technical Service Bulletins (TSBs) that may relate to this condition. Return to the Symptom List if necessary. 7. If the engine starts and continues to run, the repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, refer to the appropriate diagnostic procedure. No Repair is complete.
  5. ROAD TEST VERIFICATION TEST 1. Inspect the vehicle to verify that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. 2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and 4. If not, proceed to step 5. 3. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom no longer exists, the repair was successful and testing is now complete. 4. If the initial or another symptom exists, the repair is not complete. Check all pertinent Technical Service Bulletins (TSBs) and return to the Symptom List if necessary. 5. For previously read DTCs that have not been dealt with, return to the Symptom List and follow the diagnostic path for that DTC; otherwise, continue. 6. If the Powertrain Control Module (PCM) has been replaced, continue with step 9. 7. With the scan tool, erase all diagnostic trouble codes (DTCs), then disconnect the scan tool. 8. Turn the ignition off for at least 10 seconds. 9. If equipped with a Transfer Case Position Switch, perform step 10, otherwise, continue with step 11. 10. With the ignition switch on, place the Transfer Case Shift Lever in each gear position, stopping for 15 seconds in each position. 11. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test is for an A/C Control condition, drive the vehicle for at least 5 minutes with the A/C on. 12. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart the engine and continue. 13. Upon completion of the road test, turn the engine off and check for DTCs with the scan tool. 14. If the repaired DTC has set again, the repair is not complete. Check for any pertinent Technical Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the repair was successful and is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, refer to the appropriate diagnostic procedure. No Repair is complete.

PCM / TCM FLASH REPROGRAMMING

This procedure will need to be done when one or more of the following situations are true

  1. A vehicle's Powertrain control module (PCM) has been replaced.
  2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed.
  3. An updated calibration or software release is available for either the PCM or TCM ECUs.

This procedure assumes that the StarSCAN® and StarMOBILE® devices are configured to your dealership's network with either a wired or wireless connection. The StarSCAN® and StarMOBILE® must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN® or StarMOBILE® reference the StarSCAN® / StarMOBILE® Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > On-line Documentation' or at www.dcctools.com, under the Download Center.

Table of contents

  1. SECTION 1 - PCM / TCM FLASH PROCEDURE: GO TO «SECTION 1 - PCM / TCM FLASH PROCEDURE»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__section-1-pcm-tcm) .
  2. REQUIRED TOOLS/EQUIPMENT: GO TO «REQUIRED TOOLS/EQUIPMENT»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__required-toolsequipment) .
  3. TECH TIPS and INFORMATION: GO TO «TECH TIPS AND INFORMATION»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__tech-tips-and-information) .
  4. PARTS REQUIRED: GO TO «PARTS REQUIRED»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__parts-required) .

SECTION 1 - PCM / TCM FLASH PROCEDURE

If using StarSCAN® or StarMOBILE® Desktop Client. Go to REPAIR PROCEDURE - Using StarSCAN® or StarMOBILE® Desktop Client .

If using StarMOBILE® STANDALONE Diagnostic Mode. Go To REPAIR PROCEDURE - Using StarMOBILE® STANDALONE Diagnostic Mode .

REPAIR PROCEDURE - Using StarSCAN® or StarMOBILE® Desktop Client

Note. If this flash process is interrupted or aborted, the flash should be restarted.

  1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts.
  2. Connect the StarSCAN® or StarMOBILE® to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position.
  3. Power on the StarSCAN® or StarMOBILE®. If the StarMOBILE® is being used, launch the StarMOBILE® Desktop Client and connect to the appropriate StarMOBILE® device.
  4. Retrieve the old ECU part number. From the tool's Home screen, Select "ECU View" Select "PCM" Select "More Options" Select "ECU Flash" Record the part number at the top of the Flash PCM screen for later reference.
  5. Program the ECU as follows: Using the StarSCAN® / StarMOBILE® at the Home screen, select "ECU View" Select "PCM" Select "More Options" Select "ECU Flash" Select "Browse for New File" and follow the on screen instructions. Highlight the appropriate calibration based on the part number recorded in Step 4 e , or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. Select "Download to Scantool" Once the download is complete, select "Close" and then "Back" Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. When the PCM update is complete, select "OK" Verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted.
  6. Continue to «SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__section-2-additional-pcm) to complete the process if the ECU has been replaced.
  7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See «SECTION 3 - AUTHORIZED MODIFICATION LABEL»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__section-3-authorized-modification-label) for details).

REPAIR PROCEDURE - Using StarMOBILE® STANDALONE Diagnostic Mode

Note. StarMOBILE® STANDALONE Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE® device which DOES require a network connection. Once the file has been copied to the StarMOBILE® device, it can be used in a STANDALONE mode to flash the ECU WITHOUT a network connection.

Note. StarMOBILE® does not need to be connected to a vehicle when retrieving a flash file for STANDALONE Mode.

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Scheme 526: REPAIR PROCEDURE - Using StarMOBILE® STANDALONE Diagnostic Mode
Scheme 526: REPAIR PROCEDURE - Using StarMOBILE® STANDALONE Diagnostic Mode

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  1. Power on the StarMOBILE®. Launch the StarMOBILE® Desktop Client and connect to the tool.
  2. At the Home screen, select "ECU View" Select "PCM" Select "More Options" Select "ECU Flash" Select "Browse for New File" and follow the on screen instructions. Highlight the appropriate calibration based on the current ECU part number, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen.
  3. From the Flash File List, select the appropriate calibration for the PCM and select "Download to Client"
  4. Once the download is complete, hit "OK" and then "Manage Files"
  5. In the Manage Files screen, highlight the downloaded flash file and select "Copy to SM Device". A green check mark should now appear in the On SM Device column.
  6. Exit the StarMOBILE® Desktop Client application.
  7. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts.
  8. Connect the StarMOBILE® to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position.
  9. On the StarMOBILE® device, select "Enter STANDALONE Diagnostic Mode" (use the right function key). NOTE: If a StarMOBILE® Desktop Client is still associated with the device, you will receive the following error: "Your StarMOBILE® device is currently locked by a PC named 'xxxxxxxx' on your network. To remove the lock, close its Desktop Client or reboot this device".
  10. Program the ECU as follows: Select "ECU View" Select "PCM" Select "Flash ECU" Record the ECU part number at the very top of the screen for later reference. Highlight the flash file that you want to use. Hit "SELECT" and then "OK". Follow the on screen instructions. Once the flash is complete, verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted.
  11. Continue to «SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__section-2-additional-pcm) to complete the process if the ECU has been replaced.
  12. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See «SECTION 3 - AUTHORIZED MODIFICATION LABEL»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__section-3-authorized-modification-label) for details).

SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES

Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. Refer to STEP-BY-STEP INSTRUCTIONS .

If a NGC3 or NGC4 PCM was replaced, perform the following additional steps and/or routines

  1. PCM Replaced - if WCM equipped
  2. Learn ETC - if ETC equipped
  3. Check PCM Odometer
  4. Check PCM VIN - if NOT WCM equipped
  5. Quicklearn - if EATX equipped

If a GPEC PCM was replaced, perform the following additional steps and/or routines

  1. If the vehicle is equipped with a CVT, ensure that the TCM has the latest software calibration available (if the vehicle is not equipped with a CVT, skip to Step 3).
  2. PCM Replaced - if WCM equipped
  3. Learn ETC
  4. Check PCM Odometer
  5. Check PCM VIN - if NOT WCM equipped
  6. TCM Quicklearn - if EATX equipped

If a CVT TCM was replaced, perform the following additional steps and/or routines

  1. Initialize CVT

If an EGS TCM was replaced, perform the following additional steps and/or routines

  1. Initialize EGS

STEP-BY-STEP INSTRUCTIONS

Check PCM Odometer

From the "Home" screen, select "ECU View".

  1. Select "PCM"
  2. Select "Misc. Functions"
  3. Select "Check PCM Odometer" and follow the on screen instructions.
  4. When complete, select "Finish".

Check PCM VIN

From the "Home" screen, select "ECU View"

  1. Select "PCM"
  2. Select "Misc. Functions"
  3. Select "Check PCM VIN" and follow the on screen instructions.
  4. When complete, select "Finish"

Initialize CVT

From the "Home" screen, select "ECU View"

  1. Select "TCM"
  2. Select "Misc. Functions"
  3. Select "Initialize CVT" and follow the on screen instructions.
  4. When complete, select "Finish"

Initialize EGS

From the "Home" screen, select "ECU View"

  1. Select "TCM"
  2. Select "Misc. Functions"
  3. Select "Initialize EGS" and follow the on screen instructions.
  4. When complete, select "Finish"

Learn ETC

From the "Home" screen, select "ECU View"

  1. Select "PCM"
  2. Select "Misc. Functions"
  3. Select "Learn ETC" and follow the on screen instructions.
  4. When complete, select "Finish"

PCM Replaced

The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways

  1. The original selling invoice
  2. DealerCONNECT > Parts > Key Codes
  3. Contacting the District Manager.

From the "Home" screen, select "ECU View"

  1. Select "WCM"
  2. Select "Misc. Functions"
  3. Select "PCM Replaced" and follow the on screen instructions.
  4. When complete, select "Finish"

Quicklearn

From the "Home" screen, select "ECU View"

  1. Select "PCM"
  2. Select "Misc. Functions"
  3. Select "Quicklearn" and follow the on screen instructions.
  4. When complete, select "Finish"

Update CVT TCM

From the "Home" screen

  1. Select "ECU View"
  2. Select "TCM"
  3. Select "More Options"
  4. Select "ECU Flash"
  5. Select "Browse for New File" and follow the on screen instructions.
  6. Highlight the appropriate calibration.
  7. Select "Download to Scantool"
  8. Once the download is complete, select "Close" and then "Back"
  9. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions.
  10. When the TCM update is complete, select "OK"
  11. Verify that the part number at the top of the "Flash TCM" screen has updated to the latest level.

SECTION 3 - AUTHORIZED MODIFICATION LABEL

Note. The following step is required by law when reprogramming a PCM and/or TCM.

Type the necessary information on the "Authorized Modification Label" and attach near the VECI label.

Scheme 532

Scheme 532: SECTION 3 - AUTHORIZED MODIFICATION LABEL
Scheme 532: SECTION 3 - AUTHORIZED MODIFICATION LABEL
  1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used
  2. Change Authority: TSB XX--XX
  3. Dealer Code: XXXXX
  4. Date: XX-XX-XX

REQUIRED TOOLS/EQUIPMENT

PART NUMBERStarSCAN®PART NUMBERStarMOBILE®
NPNBattery ChargerNPNBattery Charger
CH9401StarSCAN® Tool KitCH9801StarMOBILE® Tool Kit
CH9404StarSCAN® Vehicle CableCH9804StarMOBILE® Vehicle Cable
TechCONNECT PC or equivalent

TECH TIPS AND INFORMATION

  1. StarMOBILE® STANDALONE Diagnostic Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE® device which DOES require a network connection. Once the file has been copied to the StarMOBILE® device, it can be used in a STANDALONE mode to flash the ECU WITHOUT a network connection.
  2. To use the StarMOBILE® in Pass-Through Mode requires that your StarMOBILE® is connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE® training tutorials available on 'DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > Training Aids' link or at www.dcctools.com, under the 'Training Aids' link.
  3. StarMOBILE® does not need to be connected to a vehicle when retrieving a flash file for STANDALONE Mode.
  4. Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The ECU can only be reprogrammed to a more recent version of that calibration.
  5. If the flash process is interrupted or aborted, the flash should be restarted.
  6. Due to the PCM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.
  7. When replacing a GPEC PCM for a vehicle that is equipped with a CVT, it is extremely important that the PCM and TCM both have the latest software calibrations.
  8. Do not allow the battery charger to time out or the charging rate to climb above 13.5 volts during the flash process.
  9. The StarSCAN® and StarMOBILE® diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN® / StarMOBILE® for the dealership's network, refer to the «REPAIR PROCEDURE - USING STARSCAN® OR STARMOBILE® Desktop Client»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__repair-procedure-using-starscanr-or) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > On-line Documentation' or at www.dcctools.com, under the download center.
  10. The operating software in the StarSCAN® and StarMOBILE® must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN® and StarMOBILE® Desktop Client screens. For instructions on how to update your scan tool, refer to the «REPAIR PROCEDURE - USING STARSCAN® OR STARMOBILE® Desktop Client»(/chrysler/town-country/v-2007-2010/remont/testing-diagnostics/#powertrain-control-modules-pcm-electrical-diagnosis__repair-procedure-using-starscanr-or) Software Update guide available on 'DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > On-line Documentation' or at www.dcctools.com, under the download center.

PARTS REQUIRED

QtyPart NumberDESCRIPTION
104275086ABLabel, Authorized Modification

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