jump start CHRYSLER VOYAGER 2000 Diagnostic Manual

4.3.3 ELECTRONIC PINION FACTOR
WARNING
The pinion factor must be set for all new trans-
mission control modules. If the pinion factor is not
set or if it is set incorrectly, any speed-related
accessories will not operate or will operate inaccu-
rately. This includes the speedometer, speed con-
trol, rolling door locks, and other devices that are
operated by the powertrain and body control mod-
ules. For instructions on setting the pinion factor,
see the appropriate transmission diagnostic man-
ual or the service manual.
5.0 RECOMMENDED TOOLS
AND EQUIPMENT
DRBIIIt(diagnostic readout box) scan tool
fuel pressure adapter (C-6631) or #6539
fuel pressure kit (C-4799-B) or #5069
fuel release hose (C-4799-1)
MinAir flow fitting #6457
jumper wires
ohmmeter
oscilloscope
vacuum gauge
voltmeter
12 volt test light minimum 25 ohms resistance
with probe #8382
CAUTION: A 12 VOLT TEST LIGHT SHOULD
NOT BE USED FOR THE FOLLOWING
CIRCUITS, DAMAGE TO THE POWERTRAIN
CONTROLLER WILL OCCUR.
²5 Volt Supply
²8 Volt Supply
²J1850 PCI Bus
²CCD Bus
²CKP Sensor Signal
²CMP Sensor Signal
²Vehicle Speed Sensor Signal
²O2 Sensor Signal
6.0 GLOSSARY OF TERMS
ABSantilock brake system
backfire,
popbackfuel ignites in either the intake or
the exhaust system
CKPcrank position sensor
CMPcamshaft position sensor
cuts out,
missesa steady pulsation or the inability of
the engine to maintain a consistent
rpmDLCdata link connector (previously
called ªengine diagnostic connectorº)
detona-
tion,
spark
knocka mild to severe ping, especially un-
der loaded engine conditions
ECTengine coolant temperature sensor
EGRexhaust gas recirculation valve and
system
genera-
torpreviously called ªalternatorº
hard
startThe engine takes longer than usual
to start, even though it is able to
crank normally.
hesita-
tion, sag,
stumble
There is a momentary lack of response
when the throttle is opened.
This can
occur at all vehicle speeds. If it is se-
vere enough, the engine may stall.
IATintake air temperature sensor
IACidle air control valve
JTECCombined engine and transmission
control module
lack of
power,
sluggish
The engine has less than expected
power, with little or no increase in vehi-
cle speed when the throttle is opened.
LDPLeak Detection Pump
MAPmanifold absolute pressure sensor
MILmalfunction indicator lamp
MTVmanifold tuning valve
O2Soxygen sensor
PCIProgrammable Communication In-
terface
PCMpowertrain control module
PCMpowertrain control module
PCVpositive crankcase ventilation
PEPPeripheral Expansion Port
poor fuel
economyThere is significantly less fuel mile-
age than other vehicles of the same
design and configuration
rough,
unstable,
or er-
ratic idle
stallingThe engine runs unevenly at idle
and causes the engine to shake if it
is severe enough. The engine idle
rpm may vary (called ªhuntingº).
This condition may cause stalling if
it is severe enough.
SKIMSentry Key Immobilizer Module
SKISSentry Key Immobilizer System
start and
stallThe engine starts but immediately
dies.
13
GENERAL INFORMATION
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Symptom:
P-0108 MAP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P-0108 MAP SENSOR VOLTAGE TOO HIGH
When Monitored: With engine rpm above 400 but less than 1500 and closed throttle.
Set Condition: The MAP Sensor Signal voltage is greater than 4.6.
POSSIBLE CAUSES
MAP SENSOR GROUND CIRCUIT OPEN
MAP SENSOR SIGNAL CIRCUIT OPEN
MAP SENSOR DEFECTIVE
MAP SENSOR WIRING HARN AND CONN INTERMITTENT DEF
MAP SENSOR WIRING HARNESS AND CONN OBSERVABLE DEF
PCM DEFECTIVE (MAP SENSOR VOLTAGE TOO HIGH)
TEST ACTION APPLICABILITY
1 Start the engine.
With the DRB, read the MAP Sensor voltage.
Is the MAP Sensor voltage above 4.6 volts?All
Ye s®Go To 2
No®Go To 6
2 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire between the Sensor Signal and Sensor Ground Circuits.
Turn ignition on, use the DRB to read the MAP Sensor voltage.
Is the voltage below 1.0 volt?All
Ye s®Replace the MAP Sensor.
Perform Powertrain Verification Test VER-5A.
No®Go To 3
3 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire between the Sensor Signal Circuit and an engine ground.
Ignition On.
Read the MAP Sensor voltage.
Is the MAP Sensor voltage below 1.0 volt?All
Ye s®Repair the open MAP Sensor Ground Circuit.
Perform Powertrain Verification Test VER-5A.
No®Go To 4
32
DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Turn the ignition on.
With the DRB, read the FREEZE FRAME DATA.
Using the FREEZE FRAME DATA, attempt to duplicate the condition that has set
this fault.
While using the FREEZE FRAME DATA, pay particular attention to the fault setting
conditions, such as vehicle speed, engine temperature, vehicle load, and MAP
vacuum.
Does P0121 reset?All
Ye s®Go To 6
No®Go To 5
5 Ignition Off
Start engine.
With the DRB, read the MAP Sensor voltage.
Did the MAP Sensor voltage drop from above 3.5 volts to below 2.0 volts?All
Ye s®Go To 6
No®Refer to symptom * CHECKING MAP SENSOR CALIBRATION
in the DRIVEABILITY category.
6 Ignition On, Engine Not Running
Using the schematic as a guide, wiggle the TPS Harness and Connectors to PCM.
While monitoring the DRB, observe for the TPS voltage to change.
Did the TPS voltage change at any time?All
Ye s®Repair the Harness or Connectors as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 7
7 Ignition On, Engine Not Running
With the DRB, read the Throttle Position Sensor voltage.
Is the Throttle Position Sensor voltage above 1.0 volt?All
Ye s®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
8 Ignition On, Engine Not Running
While monitoring the DRB, open the Throttle Plate to wide open throttle.
Is the Throttle Position Sensor voltage above 3.5 volts?All
Ye s®Go To 9
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
9 Ignition On, Engine Not Running
While monitoring the DRB slowly open and close the Throttle Plate.
Note: You must move linkage very slowly while looking for a jump in
voltage.
Is the voltage change smooth?All
Ye s®Go To 10
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
43
DRIVEABILITY
P-0121 TPS VOLTAGE DOES NOT AGREE WITH MAP ÐContinued
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TEST ACTION APPLICABILITY
1 Ignition Off
Raise the Drive Wheels off the ground.
Warning: Be sure to keep hands and feet clear of rotating wheels.
Start Engine.
With DRB, read the Vehicle Speed Sensor.
Put Transmission on any forward gear.
Does the DRB show above zero MPH?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 2
No®Go To 3
2 Ignition off.
Using the Schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?ENGINE -2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
3 Ignition Off
Disconnect the VSS Connector.
Note: Check connectors - Clean/repair as necessary.
Key On
Using a Voltmeter, probe the 8-Volt Power Supply Circuit.
Is the voltage above 7.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 4
No®Repair the open 8-volt Supply Circuit.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Disconnect the VSS Connector.
Note: Check connectors - Clean/repair as necessary.
Key On.
Using a Voltmeter, Probe the Vehicle Speed Sensor Signal.
Is the voltage above 4.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 5
No®Go To 11
5 Ignition Off
Disconnect the VSS Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire from the Sensor Signal to the Sensor Ground Circuit.
Key On
With the DRB, read the VSS Signal.
While observing display, tap other end of jumper to VSS Signal Circuit.
Does the display show more than 0 MPH?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 6
No®Go To 8
154
DRIVEABILITY
P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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TEST ACTION APPLICABILITY
12 Ignition Off
Disconnect the VSS Connector.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With the DRB in Ohmmeter mode, measure between the VSS Signal Circuit in the
Powertrain Control Module Connector.
Is the resistance below 5.0 ohms?ENGINE -2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Repair the Speed Sensor Signal Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 13
13 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
14 Ignition Off
Raise the Drive Wheels off the ground.
Warning: Be sure to keep hands and feet clear of rotating wheels.
Start Engine.
With DRB, read the Vehicle Speed Sensor.
Put Transmission on any forward gear.
Does the DRB show above zero MPH?ENGINE -2.0L,
2.4L, 3.3L V6 FFV
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
w/EATX
Ye s®Go To 15
No®Go To 16
15 Ignition off.
Using the Schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?ENGINE - 2.0L,
2.4L, 3.3L V6 FFV
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
w/EATX Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
16 Ignition On, Engine Not Running
With the DRB, read the EATX Trouble Codes.
Are any codes P0731- P0734, P0736, P0715, P0720, P1794 present or Pinion Factor
not programmed?ENGINE - 2.0L,
2.4L, 3.3L V6 FFV
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
w/EATX Ye s®Refer to the symptom list for problems related to Transmission.
No®Go To 17
17 Ignition Off
Disconnect the Transmission Control Module.
Note: Check connectors - Clean/repair as necessary.
Connect a Jumper Wire to the VSS Signal Circuit.
Key on.
With the DRB, read the VSS Signal.
While observing display, tap the other end of Jumper to ground.
Does the display show above zero MPH?ENGINE - 2.0L,
2.4L, 3.3L V6 FFV
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
w/EATX
Ye s®Go To 18
No®Go To 25
156
DRIVEABILITY
P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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TEST ACTION APPLICABILITY
12 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Jumper Wire connect the ASD Relay Output Circuit to Ground at the
Ignition Coil Connector.
With an Ohmmeter mesaure the ASD Output Circuit for resistance to Ground at the
Relay.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 13
No®Repair open ASD Relay Output Circuit.
Perform Powetrain Verification Test VER-1A.
13 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Ignition On, Engine Not Running.
With a Voltmeter, measure the Fused B(+) Circuit cavity B in ASD Relay Connector.
Is the voltage above 10 volts?ENGINE - 3.0L V6
Ye s®Replace the Auto Shutdown Relay.
Perform Powertrain Verification Test VER-1A.
No®Repair open Fused B+.
Perform Verification TEST VER-1A
14 Ignition Off.
Remove the Distributor Cap.
Is the Distributor Rotor loose?ENGINE - 3.0L V6
Ye s®Repair loose Distributor Rotor as necessary.
Perform Verification TEST VER-1A
No®Go To 15
15 If there are no potential causes remaining, the Distributor Drive System is assumed
to be defective.
View repair options.ENGINE - 3.0L V6
Repair
Repair the Distributor Drive System.
Perform Powertrain Verification Test VER-1A.
16 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #1.
Connect the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Warning: Ensure that there are no Fuel or Fuel vapors present in or near
the Engine compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Refer to Symptom list for further diagnostic tests.
No®Go To 17
291
STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
21 Ignition Off.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #1.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #4.
Note: Check connectors - Clean/repair as necessary.
Note: Either Spark Plug #1 or #4 will not produce a good spark.
Remove Spark Plugs #1 and #4.
Inspect and determine which Spark Plug needs replacement.
View repair options.ENGINE - 2.0L
and 2.4L I-4 DOHC
Repair
Replace the Spark Plug that will not produce a spark.
Perform Powertrain Verification Test VER-1A.
22 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect Terminals.
Is any Terminal damaged, pushed out, or miswired?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Repair Terminal(s) for damage, pushout, or miswiring.
Perform Powertrain Verification Test VER-1A.
No®Go To 23
23 Ignition On, Engine Not Running.
With the DRB, actuate Ignition Coil #1.
With a Voltmeter, measure the ASD Relay Output Circuit.
Is the voltage above 10 volts?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Replace Ignition Coil.
Perform Powertrain Verification Test VER-1A.
No®Go To 24
24 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Jumper Wire connect the ASD Relay Output Circuit to Ground at the
Ignition Coil Connector.
With an Ohmmeter, measure the ASD Relay Output Circuit for resistance to ground
at the Relay.
Is the resistance below 5.0 ohms?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Go To 25
No®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
25 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit, cavity B in ASD Relay Connector.
Is the Voltage above 10 volts?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Replace the Auto Shutdown Relay.
Perform Verification Test VER-1A
No®Repair open Fused B(+).
Perform Verification TEST VER-1A
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STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
30 Ignition On, Engine Not Running.
With the DRB, actuate Ignition Coil #1.
With a Voltmeter, measure the ASD Relay Output Circuit.
Is the voltage above 10 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Replace Ignition Coil.
Perform Powertrain Verification Test VER-1A.
No®Go To 31
31 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Jumper Wire connect the ASD Relay Output Circuit to Ground at the
Ignition Coil Connector.
With an Ohmmeter, measure the ASD Relay Output Circuit for resistance to ground
at the Relay.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 32
No®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
32 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit, cavity B in ASD Relay Connector.
Is the Voltage above 10 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Replace the Auto Shutdown Relay.
Perform Verification Test VER-1A
No®Repair open Fused B(+).
Perform Verification TEST VER-1A
295
STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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Symptom:
* NO CRANK CONDITION
POSSIBLE CAUSES
BATTERY CIRCUIT RESISTANCE TOO HIGH
FUSED B(+) CIRCUIT OPEN
STARTER RELAY CONTROL CIRCUIT OPEN
STARTER RELAY OUTPUT CIRCUIT OPEN
CRANKSHAFT NOT ABLE TO ROTATE
STARTER MOTOR DEFECTIVE
PCM DEFECTIVE (NO CRANK CONDITION)
STARTER RELAY DEFECTIVE (RESISTANCE <=100 OHMS)
STARTER RELAY DEFECTIVE (RESISTANCE ABOVE 100 OHMS)
IGNITION SWITCH OUTPUT CIRCUIT OPEN
PARK/NEUTRAL SWITCH DEFECTIVE
TEST ACTION APPLICABILITY
1Note: Ensure the SKIM has proper communication and that there are no
SKIM DTC's present before continuing.
Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Warning: The Transmission must be in Park and the Parking Brake must be
on for the next step.
Warning: The engine may be cranked in the next step. Keep away from
moving parts.
Briefly connect a jumper wire between Starter Relay Output and Fused B(+)
Circuits.
Did the Starter Motor crank the Engine?All
Ye s®Go To 2
No®Go To 9
2 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit.
Is the voltage above 11.6 volts?All
Ye s®Go To 3
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
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STARTING
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TEST ACTION APPLICABILITY
3 Ignition Off.
Ensure the Transmission is in Park.
With the DRB, read the Park/Neutral Position Switch.
Does the Switch show Park?All
Ye s®Go To 4
No®Repair Park/Neutral Switch.
Perform Powertrain Verification Test VER-1A.
4 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test the Starter Relay Terminals for resistance.
Is the resistance above 100 ohms?All
Ye s®Replace the Starter Relay.
Perform Powertrain Verification Test VER-1A.
No®Go To 5
5 Ignition Off
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a voltmeter, probe Ignition Switch Output Circuit.
While attempting to crank the engine, read the Voltmeter.
Is the voltage above 10 volts?All
Ye s®Go To 6
No®Repair the open Ignition Switch Output (Start) Circuit.
Perform Powertrain Verification Test VER-1A.
6 Ignition Off.
Disconnect the Starter Relay Connector.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an ohmmeter, test the Starter Relay Control Circuit for resistance.
Is the resistance above 5.0 ohms?All
Ye s®Repair the open Starter Relay Control Circuit.
Perform Powertrain Verification Test VER-1A.
No®Go To 7
7 Ignition Off
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Warning: The Transmission must be in park and the Parking Brake must be
on for the next step.
Warning: The Engine may be cranked in the next step. Keep away form
moving Engine parts.
Connect a jumper wire between the Starter Relay Control Circuit and ground.
Briefly turn the Ignition to the crank position and then release.
Did the Engine crank?All
yes
Go To 8
no
Replace the Starter Relay.
Perform Powertrain Verification Test VER-1A.
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STARTING
* NO CRANK CONDITION ÐContinued
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