fuel filter CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
18 Ignition Off
Inspect the Chassis Fuel Supply Line to engine for a kink or restriction.
Is the Fuel Line kinked or restricted?ENGINE - 3.0L V6
Ye s®Release the Fuel Pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 19
19 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Install Fuel Pressure Gauge between Fuel Tank and Fuel Filter.
Key on.
With the DRB, actuate the ASD Fuel System test.
Is fuel pressure at least 5 psi higher than the previously recorded pressure?ENGINE - 3.0L V6
Ye s®Release the Fuel Pressure. Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Go To 20
20 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Install Fuel Pressure Gauge between Fuel Tank and Fuel Filter.
Key on.
With the DRB, actuate the ASD Fuel System test.
Is fuel pressure at least 5 psi higher than the previously recorded pressure?ENGINE - 3.0L V6
Ye s®Test Complete.
No®Release the Fuel Pressure. Replace the Fuel Pump and Regulator
Assembly.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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Symptom:
* CHECKING THE FUEL SYSTEM
POSSIBLE CAUSES
FUEL PUMP GROUND CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN
FUEL PUMP RELAY FUSED B(+) CIRCUIT OPEN
FUEL PUMP RELAY FUSED B(+) CIRCUIT OPEN
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL FILTER DEFECTIVE
FUEL FILTER DEFECTIVE
FUEL PUMP DEFECTIVE
FUEL PUMP DEFECTIVE
FUEL PUMP RELAY
FUEL PUMP RELAY
IN-TANK FUEL PRESSURE REGULATOR DEFECTIVE
IN-TANK FUEL PRESSURE REGULATOR DEFECTIVE
THROTTLE POSITION SENSOR DEFECTIVE
FUEL FILTER DEFECTIVE
FUEL FILTER DEFECTIVE
FUEL INLET STRAINER DEFECTIVE
FUEL INLET STRAINER DEFECTIVE
FUEL PUMP MODULE DEFECTIVE
FUEL PUMP MODULE DEFECTIVE
FUEL SUPPLY LINE DEFECTIVE
FUEL SUPPLY LINE DEFECTIVE
FUEL TUBE RESTRICTED
FUEL TUBE RESTRICTED
POWERTRAIN CONTROL MODULE DEFECTIVE
POWERTRAIN CONTROL MODULE DEFECTIVE
THROTTLE CABLES DEFECTIVE
THROTTLE CABLES DEFECTIVE
THROTTLE POSITION SENSOR DEFECTIVE
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TEST ACTION APPLICABILITY
1Note: Ensure the SKIM has proper communication and that there are no
SKIM DTC's present before continuing.
Ignition Off.
Ensure the Throttle Cables are not holding the Throttle open.
Is the Throttle held open?ENGINE - 3.0L V6
Ye s®Repair condition that holds the Throttle Body open.
Perform Powertrain Verification Test VER-1A.
No®Go To 2
2 Ignition On, Engine Not Running
With the DRB, actuate the Fuel System and check for Fuel Pump operation at the
Fuel Tank.
Is the Fuel Pump operating?ENGINE - 3.0L V6
Ye s®Go To 3
No®Go To 13
3 Ignition On, Engine Not Running
With DRB, read Throttle Position Sensor voltage.
Is the voltage above 1.5 volts?ENGINE - 3.0L V6
Ye s®Disconnect the TP Sensor Conn. Replace Throttle Position Sensor.
Perform Powertrain Verification Test VER-1A.
No®Go To 4
4 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Install a Fuel Pressure Gauge to the Fuel Rail.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 psi for Gasoline.
Is the Fuel pressure above the specification ?ENGINE - 3.0L V6
Ye s®Go To 5
No®Go To 8
5 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 6
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STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
6 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Go To 7
No®Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-1A.
7 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Return Tube for restriction between fuel Filter and Fuel Pump Module.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Replace restricted Fuel Tube.
Perform Powertrain Verification Test VER-1A.
No®Test Complete.
8 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Tee-In a Fuel Pressure Gauge into the Fuel Hose using tool #6433.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 psi for Gasoline.
Is the Fuel pressure below the specification ?ENGINE - 3.0L V6
Ye s®Go To 9
No®Test Complete.
9 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove adapter 6631 and reinstall Fuel Line.
Install adapter 6631 between Fuel Pump and Fuel Filter.
Connect Fuel Pressure Gauge to adapter 6631.
Key on.
With the DRB, actuate Fuel System.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 3.0L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 10
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STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
10 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pump Module.
Inspect the Fuel Pump Inlet Strainer.
Is the Inlet Strainer plugged?ENGINE - 3.0L V6
Ye s®Replace the Fuel Inlet Strainer.
Perform Powertrain Verification Test VER-1A.
No®Go To 11
11 Record the Fuel Pressure Gauge reading.
Ignition key off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pressure Gauge.
Remove Fuel Pressure Gauge Adapter 6433 and reconnect Fuel Line to Fuel Rail.
Install adapter 6631 between Fuel Filter Outlet and Chassis Fuel Supply Tube.
Connect Fuel Pressure Gauge to adapter 6631.
Ignition On, Engine Not Running.
With DRB, actuate the ASD Fuel System.
Record the Fuel Pressure Gauge reading.
Compare this reading with the previous reading.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 3.0L V6
Ye s®Repair restriction in Chassis Fuel Supply Line between Fuel
Filter and Fuel Rail.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
12 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.ENGINE - 3.0L V6
Repair
Replace Fuel Pump Module.
Perform Powertrain Verification Test VER-1A.
13 Ignition On, Engine Not Running
With DRB, read Throttle Position Sensor voltage.
Is the voltage above 1.5 volts?ENGINE - 3.0L V6
Ye s®Disconnect the TP Sensor Conn. Replace Throttle Position Sensor.
Perform Powertrain Verification Test VER-1A.
No®Go To 14
14 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note: Check connectors - Clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
With an Ohmmeter, measure the Fuel Pump Ground Circuit.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 15
No®Repair the open Fuel Pump Ground Circuit.
Perform Powertrain Verification Test VER-1A.
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STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
20 Ignition On, Engine Not Running
With the DRB, actuate the Fuel System and check for Fuel Pump operation at the
Fuel Tank.
Is the Fuel Pump operating?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 21
No®Go To 30
21 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Install a Fuel Pressure Gauge to the Fuel Rail.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
For 3.3 liter engines fuel pressure should be 50 to 60 psi, and for all other engines fuel
pressure should be 43 to 53 psi.
Is the Fuel pressure above the specification ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 22
No®Go To 25
22 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 23
23 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 24
No®Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-1A.
283
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
24 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Return Tube for restriction between fuel Filter and Fuel Pump Module.
Is there a restriction ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace restricted Fuel Tube.
Perform Powertrain Verification Test VER-1A.
No®Test Complete.
25 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Tee-In a Fuel Pressure Gauge into the Fuel Hose using tool #6433.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 PSI for Gasoline, 50 to 60 PSI for (E85) Ethanol.
Is the Fuel pressure below the specification ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 26
No®Test Complete.
26 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove adapter 6631 and reinstall Fuel Line.
Install adapter 6631 between Fuel Pump and Fuel Filter.
Connect Fuel Pressure Gauge to adapter 6631.
Key On.
With the DRB, actuate Fuel System.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 27
27 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pump Module.
Inspect the Fuel Pump Inlet Strainer.
Is the Inlet Strainer plugged?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Inlet Strainer.
Perform Powertrain Verification Test VER-1A.
No®Go To 28
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STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
28 Record the Fuel Pressure Gauge reading.
Ignition Key Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pressure Gauge.
Install adapter 6631 between Fuel Filter Outlet and Chassis Fuel Supply Tube.
Connect Fuel Pressure Gauge to adapter 6631.
Ignition On, Engine Not Running.
With DRB, actuate the ASD Fuel System.
Record the Fuel Pressure Gauge reading.
Compare this reading with the previous reading.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Repair restriction in Chassis Fuel Supply Line between Fuel
Filter and Fuel Rail.
Perform Powertrain Verification Test VER-1A.
No®Go To 29
29 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Repair
Replace Fuel Pump Module.
Perform Powertrain Verification Test VER-1A.
30 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note: Check connectors - Clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
With an Ohmmeter, measure the Fuel Pump Ground Circuit.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 31
No®Repair the open Fuel Pump Ground Circuit.
Perform Powertrain Verification Test VER-1A.
31 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Ignition On , Engine Not Running.
With a Voltmeter, measure the Fuel Pump Relay Fused B(+) Circuit.
Is the voltage above 10.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 32
No®Repair the open Fuel Pump Relay Fused B(+) Circuit.
Perform Powertrain Verification Test VER-1A.
285
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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Verification Tests
VERIFICATION TEST VER-1A APPLICABILITY
No Start Verification
Use this test to verify that a No Start condition has been repaired and that the vehicle can be
returned to the customer.
Note: If the Powertrain Control Module has been replaced and the correct VIN and
mileage have not been programmed, a DTC will be set in the ABS, Airbag and the
SKIM modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer
Module (SKIM), Secret Key data must be updated to enable starting. Refer to
GENERAL INFORMATION section for programming information for the PCM, SKIM
and the Transponder (ignition key).
1. Inspect the vehicle to ensure that all components related to the repair are connected
properly.
2. Inspect the engine oil for fuel contamination. Replace the oil and filter as necessary
3. Attempt to start the engine.
4. If the No Start condition is still present, refer to the symptom list and perform diagnostic
testing as necessary. Refer to any Technical Service Bulletins that may apply.
5. Run the engine for one warm-up cycle to verify proper operation. With the DRBIIIt, confirm
that no DTC's are present and that all components are functioning properly.
6. If DTC's are present, refer to the symptom list and perform diagnostic testing as necessary.ALL
VERIFICATION TEST VER-2A APPLICABILITY
Non-OBDII Verification
Use this test to verify that a non-OBDII symptom has been repaired and that the vehicle can
be returned to the customer. A non-OBDII symptom is a comprehensive component related
symptom that is not the result of a failed OBDII major monitor.
Note: If the Powertrain Control Module has been replaced and the correct VIN and
mileage have not been programmed, a DTC will be set in the ABS, Airbag and the
SKIM modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer
Module (SKIM), Secret Key data must be updated to enable starting. Refer to
GENERAL INFORMATION section for programming information for the PCM, SKIM
and the Transponder (ignition key).
1. Inspect the vehicle to ensure that all components related to the repair are connected
properly.
2. With the DRBIIIt, Clear DTC's and Reset Memory (all engine values).
3. Run the engine for one warm-up cycle to verify proper operation.
4. Road test the vehicle. Use all accessories that may be related to this repair.
With the DRBIIIt, confirm that no DTC's are present and that all components are functioning
properly.
6. If this test is being performed after a No Trouble Code test, verify that the symptom is no
longer present. If the symptom is still present, or any other symptom or DTC is present, refer
to the symptom list for further diagnostic testing procedures. Check for any Technical Service
Bulletins that may apply.
7. If there are no DTC's present and all components are functioning properly, repair is
complete.ALL
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VERIFICATION TESTS
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Powertrain Verification Test VER-7A APPLICABILITY
SKIS Verfication
Use this test to verify that SKIM system symptom has been repaired and that the vehicle can
be returned to the customer.
Note: If the Powertrain Control Module has been replaced and the correct VIN and
mileage have not been programmed, a DTC will be set in the ABS, Airbag and SKIM
modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer
Module (SKIM), Secret Key data must be updated to enable starting. Refer to
GENERAL INFORMATION section for programmig information for the PCM, SKIM
and the Transponder (ignition key).
1.Inspect the vehicle to ensure that all components related to the repair are connected properly.
2. Inspect the engine oil for fuel contamination. Replace the oil and filter as necessary.
3. Start the engine.
4. Run the engine for one warm-up cycle to verify proper operation. With the DRBIIIt, confirm
that no DTCs are present and that all components are functioning properly. If the DTC is still
present refer to any Technical Service Bulletins that may apply.
5. If a different DTC(s) is present, refer to the symtom list and perform diagnostic testing as
necessary. If there are no DTCs present and all components are functioning correctly, repair is
now complete.All
322
VERIFICATION TESTS
Verification Tests ÐContinued
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