ignition CHRYSLER VOYAGER 2000 Diagnostic Manual

to non-emission codes, they will seem like an intermit-
tent. These codes require a set of parameters to be
performed (The DRBIIItpre-test screens will help
with this for MONITOR codes), this is called a ªTRIPº.
All EURO STAGE III OBD DTCs will be set after one
or in some cases two trip failures, and the MIL will be
turned on. These codes require three successful (no
failures) TRIPS to extinguish the MIL, followed by 40
warm-up cycles to erase the code.
3.3.2 INTERMITTENT CODE
A diagnostic trouble code that is not there every
time the PCM checks the circuit is an ªintermittentº
code. Most intermittent codes are caused by wiring
or connector problems. Defects that come and go
like this are the most difficult to diagnose; they
must be looked for under specific conditions that
cause them. The following checks may assist you in
identifying a possible intermittent problem:
²Visually inspect related wire harness connectors.
Look for broken, bent, pushed out, or corroded
terminals.
²Visually inspect the related harnesses. Look for
chafed, pierced, or partially broken wire.
²Refer to any Hotline Newsletters or technical
service bulletins that may apply.
²Use the DRBIIItdata recorder or co-pilot.
²Use the DRBIIItPEP module lab scope.
3.3.3 RESET COUNTER
The reset counter counts the number of times the
vehicle has been started since codes were last set,
erased, or the battery was disconnected. The reset
counter will count up to 255 start counts.
The number of starts helps determine when the
trouble code actually happened. This is recorded by
the PCM and can be viewed on the DRBIIItas
STARTS since set.
When there are no trouble codes stored in mem-
ory, the DRBIIItwill display ªNO DTC'S Detectedº
and the reset counter will show ªSTARTS since
clear = XXX.º
3.3.4 HANDLING NO TROUBLE CODE
PROBLEMS
Symptom checks cannot be used properly unless
the driveability problem characteristic actually
happens while the vehicle is being tested.
Select the symptom that most accurately de-
scribes the vehicle's driveability problem and then
perform the test routine that pertains to this symp-
tom. Perform each routine test in sequence until the
problem is found. For definitions, see Section 6.0
Glossary of Terms.SYMPTOM DIAGNOSTIC TEST
HARD START CHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING ENGINE VAC-
UUM
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING ENGINE ME-
CHANICAL SYSTEMS
CHECKING EVAP EMISSION
SYSTEM
CHECKING EGR SYSTEM
CHECKING IAT SENSOR
START AND
STALLCHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
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GENERAL INFORMATION
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CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
HESITATION/
SAG/
STUMBLECHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING ENGINE VAC-
UUM
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING O2S HEATER
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING ENGINE ME-
CHANICAL SYSTEMS
CHECKING EVAP EMISSION
SYSTEM
CHECKING EGR SYSTEM
CHECKING IAT SENSOR
CHECKING PNP SWITCH
SURGE CHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATIONCHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EVAP EMISSION
SYSTEM
LACK OF
POWER/
SLUGGISHCHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EGR SYSTEM
SPARK
KNOCK/
DETONATIONCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
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GENERAL INFORMATION
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CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EVAP EMISSION
SYSTEM
CUTS OUT/
MISSESCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EGR SYSTEM
BACKFIRE/
POPBACKCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING EGR SYSTEM
RUNS
ROUGH/
UNSTABLE/
ERRATIC
IDLECHECKING SECONDARY
IGNITION SYSTEMCHECKING PCM POWER
AND GND CKT
CHECKING ENGINE VAC-
UUM
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING O2S HEATER
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING ENGINE ME-
CHANICAL SYSTEMS
CHECKING EVAP EMISSION
SYSTEM
CHECKING EGR SYSTEM
CHECKING IAT SENSOR
CHECKING PNP SWITCH
POOR FUEL
ECONOMYCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING ENGING VAC-
UUM
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
10
GENERAL INFORMATION
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applicable. These procedures can be found in ser-
vice manual procedures. Following these proce-
dures is very important to the safety of individuals
performing diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced in assembly only. Attempt-
ing to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRB MULTIMETER IS DANGEROUS. IT CAN
EXPOSE YOU TO SERIOUS INJURY.
CAREFULLY READ AND UNDERSTAND THE
CAUTIONS AND THE SPECIFICATION
LIMITS.
Follow the vehicle manufacturer 's service specifi-
cations at all times.
²Do not use the DRBIIItif it has been damaged.
²Do not use the test leads if the insulation is
damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test
leads, tips or the circuit being tested.
²Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
²Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 -1.12 megohms
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100ÉF
-50 - 600ÉC
* Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
²Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
²Use caution when measuring voltage above 25v
DC or 25v AC.
²The circuit being tested must be protected by a
10A fuse or circuit breaker.
²Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeding 10A.
²When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before accepting a zero reading.
²When measuring current, connect the meter in
series with the load.
²Disconnect the live test lead before disconnecting
the common test lead.
²When using the meter function, keep the DRB
away from spark plug or coil wires to avoid
measuring error from outside interference.
4.3 WARNINGS AND CAUTIONS
4.3.1 ROAD TEST WARNINGS
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL
COMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRB SCREEN WHILE IN MOTION.
DO NOT HANG THE DRB FROM THE REAR
VIEW MIRROR OR OPERATE IT YOURSELF.
HAVE AN ASSISTANT AVAILABLE TO
OPERATE THE DRB.
4.3.2 VEHICLE DAMAGE CAUTIONS
Before disconnecting any control module, make
sure the ignition is ªoffº. Failure to do so could
damage the module.
When testing voltage or continuity at any control
module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the
insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second code could be set, making diagnosis of the
original problem more difficult.
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GENERAL INFORMATION
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Symptom:
P-0622 GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored and Set Condition:
P-0622 GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored: With the ignition key on and the engine not running.
Set Condition: This trouble code sets when the PCM tries to regulate the generator field
with no result during monitoring.
POSSIBLE CAUSES
GENERATOR FIELD RESISTANCE > = 5.0 OHMS
ASD WIRING HARNESS INTERMITTENT DEFECT
ASD WIRING HARNESS OBSERVABLE DEFECT
GENERATOR FIELD DRIVE CIRCUIT SHORT TO GROUND
GENERATOR FIELD DRIVER CIRCUIT OPEN
PCM DEFECTIVE (GENERATOR)
ASD RELAY OUTPUT CIRCUIT OPEN
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running.
With the DRB, actuate the Generator Field Driver Circuit.
Backprobe the ASD Relay Output Circuit at the back of the Generator.
Is the voltage above 10.0 volts?All
Ye s®Go To 2
No®Repair the open ASD Relay Output Circuit, Generator to Harness
Splice.
2 Engine Running
With the DRB, actuate the Generator Field Driver Circuit.
Backprobe the Generator Field Driver Circuit at the back of the Generator.
Does the voltage shift from low to high?All
Ye s®Go To 3
No®Go To 5
3 Ignition On, Engine Not Running.
With the DRB, actuate the Generator Field Driver Circuit.
With the DRB, read codes.
Wiggle Wiring Harness from the Generator to PCM.
Does the Generator Field Driver Circuit code return?All
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-3A.
No®Go To 4
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CHARGING
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TEST ACTION APPLICABILITY
4 Ignition Off.
Using the schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-3A.
No®Test Complete.
5 Ignition Off
Disconnect the PCM.
Disconnect the Generator Field Harness Connector at back of the Generator.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test resistance across the Generator Field Terminals.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Generator as necessary.
Perform Powertrain Verification Test VER-3A.
6 Ignition Off
Disconnect the PCM.
Disconnect the Generator Field Harness Connector at back of the Generator.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of Generator Field Driver Circuit from
the at Generator Harness Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Generator Field Driver Circuit short to ground.
Perform Powertrain Verification Test VER-3A.
No®Go To 7
7 Ignition Off
Disconnect the PCM.
Disconnect the Generator Field Harness Connector at back of the Generator.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test the resistance of the Generator Field Driver Circuit
Generator Connector to PCM Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair open Generator Field Driver Circuit Generator to PCM.
Perform Powertrain Verification Test VER-3A.
8 Ignition Off
If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-3A.
17
CHARGING
P-0622 GENERATOR FIELD NOT SWITCHING PROPERLY ÐContinued
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Symptom List:
P-1492 BATTERY TEMP SENSOR VOLTAGE TOO HIGH
P-1493 BATTERY TEMP SENSOR VOLTAGE TOO LOW
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P-1492 BATTERY TEMP SENSOR
VOLTAGE TOO HIGH.
When Monitored and Set Condition:
P-1492 BATTERY TEMP SENSOR VOLTAGE TOO HIGH
When Monitored: With the ignition key on.
Set Condition: The PCM senses the voltage from the BTS to be either below 0.1 volts or
above 4.9 volts for 3 seconds.
P-1493 BATTERY TEMP SENSOR VOLTAGE TOO LOW
When Monitored: With the ignition key on.
Set Condition: The PCM senses the voltage from the BTS to be either below 0.1 volts or
above 4.9 volts for 3 seconds.
POSSIBLE CAUSES
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the Trouble Codes.
Does the DRB show9Battery Temperature Sensor Voltage9with a run count of zero?All
Ye s®Replace the PCM.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
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CHARGING
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Symptom:
P-1594 CHARGING SYSTEM VOLTAGE TOO HIGH
POSSIBLE CAUSES
GENERATOR FIELD DRIVER CIRCUIT SHORT TO GROUND
GENERATOR SHORTED
PCM DEFECTIVE (CHARGING SYSTEM)
PCM BATT TEMP NOT W/I þ12 DEGREES C (10 DEGREES F) UNDER HOOD TEMP
PCM VOLT & TARGET CHARGING VOLT DIFFER BY > 1.0 V
TEST ACTION APPLICABILITY
1 Ignition on, engine not running.
Note: Battery must be fully charged.
Note: Generator Belt tension and condition must be checked before con-
tinuing.
With the DRB, actuate the Generator Field Driver.
Using a voltmeter, backprobe the Generator Field Driver Circuit voltage in back of
Generator.
Does the DRB show voltage shift low to high?All
Ye s®Go To 2
No®Go To 6
2 Ignition On, Engine Not Running
With the DRB, stop the Generator Field Driver actuation.
Read the target charging voltage.
Is the target charging voltage between 13.0 to 14.9 volts?All
Ye s®Test Complete.
No®Go To 3
3 Engine running.
Manually set the engine speed to 1600 RPM.
With the DRB, read both the voltage and the target charging voltage.
Compare the9target9to the9volt9reading.
Watch for up to 5 minutes, if necessary, for a 1.0 volt difference or more.
Was there more than a 1.0 volt difference?All
Ye s®Replace PCM.
Perform Powertrain Verification Test VER-3A.
No®Go To 4
4 Ignition On, Engine Not Running
Using the DRB Temperature Probe, measure the under hood temperature near PCM.
With the DRB, read the BTS temperature.
Is the Battery Temperature within þ12 degrees C (10 degrees F) of the under hood
temperature?All
Ye s®Go To 5
No®Replace PCM.
Perform Powertrain Verification Test VER-3A.
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CHARGING
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TEST ACTION APPLICABILITY
5 Turn ignition on, engine not running.
Erase trouble codes.All
Refer to symptom * CHARGING SYSTEM NO CODE TEST in the
CHARGING category.
6 Ignition Off
Disconnect the Field Harness Connector at back of Generator.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure resistance of one of the Generator Field Terminals at
the Generator to Ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair or replace the shorted Generator as necessary.
Perform Powertrain Verification Test VER-3A.
No®Go To 7
7 Ignition Off
Disconnect the PCM Connector.
Disconnect the Field Harness Connector at back of Generator.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the Generator Field Driver Circuit from PCM Connec-
tor to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Generator Field Driver Circuit short to ground.
Perform Powertrain Verification Test VER-3A.
No®Go To 8
8 Ignition off.
If there are no potential causes remaining, the PCM is assumed to be defective.
View repair optionsAll
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-3A.
20
CHARGING
P-1594 CHARGING SYSTEM VOLTAGE TOO HIGH ÐContinued
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Symptom:
P-1682 CHARGING SYSTEM VOLTAGE TOO LOW
When Monitored and Set Condition:
P-1682 CHARGING SYSTEM VOLTAGE TOO LOW
When Monitored: With no other charging system codes set. With the ignition on and the
engine running above 1500 RPM.
Set Condition: The battery sensed voltage is 1 volt below the charging system goal for 25
seconds. The PCM senses the battery voltage, turns off the field driver and senses the
battery voltage again. If the voltages are the same, the code is set.
POSSIBLE CAUSES
ASD RELAY OUTPUT CIRCUIT OPEN
GENERATOR FIELD DRIVER CIRCUIT OPEN
GENERATOR DEFECTIVE
GENERATOR DEFECTIVE (B)
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Start engine, and allow it to idle.
Note: Battery must be fully charged.
Note: Generator Belt tension and condition must be checked before con-
tinuing.
With the DRB, read the Target Charging voltage.
Is the Target Charging voltage above 15.1 volts?All
Ye s®Go To 2
No®Go To 6
2 Ignition On, Engine Not Running
Using DRB Temperature Probe, measure the under hood temperature near PCM.
With the DRB, read the Ambient/BAT Temp.
Is the battery temperature within þ12 degrees C (10 degrees) of the under hood
temperature?All
Ye s®Go To 3
No®Replace the PCM.
Perform Powertrain Verification Test VER-3A.
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CHARGING
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