2004 Chrysler Pacifica SUV Service Manual (P/N 81-699-01050)

• 370-page DaimlerChrysler factory powertrain diagnostic publication covering the 2004 Chrysler Pacifica (CS) with the 3.5L engine and its Next Generation Controller (NGC) PCM.
• Provides test coverage for more than 130 listed P- and U-code DTCs, plus no-code complaints involving module communication, fuel delivery, hard starting, crank/no-start, no-crank, and start-and-stall conditions.
• Covers DRB III scan-tool communication, OBDII/Euro Stage III monitor operation, CARB readiness, PCM/SKREEM/ignition-key programming, and powertrain verification after repair.
• Provides component-location views and nearly 60 connector and pinout references for the PCM, IPM, DLC, SKREEM, NVLD assembly, sensors, injectors, coils, relays, and output devices.
• Includes three 2004 CS 3.5L system schematics plus vacuum-gauge fault patterns, NGC cam/crank scope patterns, and EVAP smoke-test/NVLD reference illustrations.
• Focused on diagnosis and fault isolation; this volume directs component removal and physical repair work to the separate service information.

Diagnostic and Control System Overview

This PDF is the powertrain diagnostic-procedures volume for the 2004 CS/Pacifica equipped with the 3.5L gasoline engine. The vehicle uses the NGC architecture, with the powertrain and transmission controllers combined in one module that the manual identifies as the PCM. Four color-coded 38-way PCM connectors are documented individually, which matters when selecting a circuit test, pinout, or breakout-box connection.

The manual opens with Chrysler's six-step troubleshooting framework: verify the complaint, check related symptoms, analyze the condition, isolate the fault, repair the identified problem, and verify correct operation. It also establishes the correct starting point for scan-tool work. A DRB III No Response condition must be resolved before the technician moves into a DTC or symptom test.

Functional-operation coverage goes beyond code definitions. The text explains speed-density sequential fuel injection, crank and warm-up fuel strategies, open- and closed-loop PCM operation, oxygen-sensor feedback, charging control, speed control, and Natural Vacuum Leak Detection. A separate non-monitored-circuits section identifies faults the PCM may not recognize directly, including restricted fuel delivery, incorrect mechanical timing, low or uneven compression, exhaust restrictions, and certain injector problems. That distinction helps prevent an electrical code from being treated as proof that the named sensor or module is the actual cause.

OBDII/Euro Stage III material covers MIL strategy, one- and two-trip faults, hard and intermittent codes, starts-since-set and distance-since-MIL data, DRB III error messages, and the monitor-run process used to establish CARB readiness. Monitor coverage includes NVLD/purge, catalyst and oxygen-sensor response, EGR, and oxygen-sensor heater operation.

The diagnostic section is organized around communication faults, NGC driveability codes, SKREEM faults, starting complaints, and verification tests. Coverage spans crank/cam correlation, MAP, IAT, ECT and TPS circuits, fuel-trim and injector faults, misfire, ignition-coil ionization, EGR, catalyst efficiency, EVAP/NVLD leaks, fuel-level sensing, cooling-fan and idle-air control, charging, speed control, PCM programming, relay circuits, and PCI-bus message failures. Symptom paths address PCM or SKREEM no-response conditions, PCM power and grounds, fuel pressure and leak-down, hard starting, engine-cranks/no-start, no-crank, and start-and-stall complaints.

Technical Reference and Specification Highlights

The SKREES material explains how the ignition-key transponder, SKREEM, and PCM exchange coded messages before continued engine operation is authorized. It also covers DRB III programming functions for PCM replacement, SKREEM replacement, and ignition keys, along with faults such as invalid or unprogrammed keys, antenna failure, rolling-code failure, VIN mismatch, and transponder communication or ID errors.

Several programming traps are documented clearly. The PCM/SKREEM replacement sequence affects whether existing keys remain usable, and programming an incorrect country code into a replacement SKREEM requires replacement of that module. A key already learned to a different vehicle cannot be transferred to this system.

Factory tool references include the DRB III, Miller #8815 Diagnostic Pinout Box, Miller #3638 Terminal Removal Tool, Evaporative Emissions Leak Detector #8404, EVAP Diagnostic Kit #6917, and the specified fuel-pressure adapters and gauge kits. The connector section covers PCM C1-C4, IPM C1-C9, the data link connector, SKREEM, NVLD, oxygen sensors, coils, injectors, fan circuits, relays, and other controlled devices.

The three powertrain schematics divide the electrical system into useful diagnostic groups: starter, fuel-pump, fan, A/C-clutch, and manifold-tuning relay circuits; PCM sensor, O2, knock, EVAP/NVLD, EGR, and data-link circuits; and injector, ignition-coil, speed-control, brake-switch, generator, and idle-air-control circuits. Final charts show vacuum-gauge patterns for mechanical engine faults, NGC cam/crank scope patterns, and EVAP smoke-machine/NVLD adapter arrangements.

Electrical testing cautions are specific to this controller. The manual requires the #8815 pinout box for PCM terminal checks and warns that direct probing can damage terminals; piercing wire insulation can also create later corrosion failures. It further prohibits a 12-volt test light on low-voltage supply, data-bus, crank/cam, vehicle-speed, and O2 signal circuits. Fuel-system tests require pressure to be released before lines or fittings are opened, and road-test verification should be performed with an assistant operating the scan tool.