warning CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
4 To continue testing you will need Miller Tool Kit #6872A, #8382 and #6904 Ultrasonic
Leak Detector.
NOTE: The Fuel Tank must have 1/2 tank of fuel to perform this test.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Warning: Verify the vehicle fuel tank contains at least 3 gallons of fuel.
Attach the DRB III to the vehicle.
Turn the Key On.
At: ENGINE SYSTEM TESTS select: LEAK DETECTION PUMP TEST.
Read instructions and then press ENTER.
At: LEAK DETECTION PUMP TEST select #3 HOLD PSI.
At the vacuum hose going to the LDP, attach and apply a continuous vacuum (i.e. 209
Hg).
Remove Gas Cap.
Install 8382 on the Gas Cap and on the vehicle.
Attach the supply hose from 6872A to 8382.
Attach the power source from the 6872A, clip to Battery(+) and ground clip to
Battery(-).
Set Pressure Hold to Open and set Vent to Open.
Turn Pump Timer On.
To prevent noise from interfering with test, move tool #6872 away from vehicle.
Using the Ultrasonic Leak Detector, start listening for leaks at Gas Cap then proceed
to Rollover Valve, Canister, Leak Detection Pump, and Evap Purge Solenoid.
Were any leaks heard with the Ultrasonic Leak Detector?All
Ye s®Repair or replace leaking component.
Perform VERIFICATION TEST VER-6A.
No®Replace Leak Detection Pump.
Perform VERIFICATION TEST VER-6A.
5 At this time, the condition required to set the code is not present.
Using the schematic as a guide, inspect the wiring, connectors and hoses.
Were any problems found?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-6A.
No®Test Complete.
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DRIVEABILITY
P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED 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
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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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Symptom:
* CHECKING FUEL DELIVERY
POSSIBLE CAUSES
FUEL LINE RESTRICTED
FUEL FILTER DEFECTIVE
FUEL LINE RESTRICTED
FUEL PRESSURE REGULATOR DEFECTIVE
FUEL PUMP/REGULATOR ASSEMBLY DEFECTIVE
FUEL RETURN LINE DEFECTIVE
FUEL PUMP/REGULATOR ASSEMBLY DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel Pressure.
Connect a Fuel Pressure Gauge to test port.
Ignition On, Engine Not Running
With the DRB, actuate Fuel System. Fuel Pressure should be 43 to 53 psi.
Fuel Pressure should be 43 to 53 psi.
Is the Fuel Pressure within the specification?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Go To 2
No®Go To 5
2 Ignition Off
Note: Make sure the Gear Lever is in neutral, and the Park Brakes engaged.
Start the engine.
Monitor the Fuel Pressure Gauge in the next step.
While monitoring the pressure, momentarily snap Throttle wide open raising RPM to
above 3000.
Did the fuel pressure drop below 35 psi at all?All
Ye s®Go To 3
No®Test Complete.
3 Ignition Off
Inspect the Chassis Fuel Supply Line to the engine for a kink or restriction.
Is the line kinked or restricted?All
Ye s®Release the fuel pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Adjust a shop air hose to 40 psi.
Remove the Fuel Filter.
Using shop air, inspect the Fuel Filter passage by attempting to blow air through
inlet.
Is the Fuel Filter restricted?All
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Replace the Fuel Pump and Regulator Assembly.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel Pressure.
Connect a Fuel Pressure Gauge to test port.
Ignition On, Engine Not Running.
With the DRB, actuate Fuel System. Fuel Pressure should be 43 to 53 psi for Gasoline
Engines and 50 to 60 psi for Flexible Fuel Vehicle.
Record the Fuel Pressure reading.
Is the Fuel Pressure above the specification?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Go To 6
No®Go To 8
6 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Remove the Fuel Return Line between the Fuel Tank and Filter.
Adjust a shop air hose to 40 psi.
Using shop air, inspect the Fuel Line by attempting to blow air through it.
Is the Fuel Return Line restricted?All
Ye s®Replace the Fuel Return Line.
Perform Powertrain Verification Test VER-2A.
No®Go To 7
7 If there are no potential causes remaining, the Fuel Pressure Regulator is assumed
to be defective.
View repair options.All
Repair
Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-2A.
238
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Inspect the Chassis Fuel Supply Line to engine for a kink or restriction.
Is the Line kinked or restricted?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 9
9 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is the Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Go To 10
10 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Test Complete.
No®Release the Fuel Pressure. Replace the Fuel Pump and Regulator
Assembly.
Perform Powertrain Verification Test VER-2A.
11 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Relieve the Fuel Pressure.
Tee-in Fuel Pressure Gauge into the Fuel Supply Hose using Tool #6433.
Turn ignition on.
With the DRB, actuate the ASD Fuel System test.
Is the Fuel Pressure between 43 and 53 psi?ENGINE - 3.0L V6
Ye s®Go To 12
No®Go To 15
12 Ignition Off
Note: Make sure the Gear Lever is in neutral, and the Park Brakes engaged.
Start the engine.
Monitor the Fuel Pressure Gauge in the next step.
While monitoring the pressure, momentarily snap Throttle wide open raising RPM to
above 3000.
Did the fuel pressure drop below 35 psi at all?All
Ye s®Go To 13
No®Test Complete.
239
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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TEST ACTION APPLICABILITY
13 Ignition Off
Inspect the Chassis Fuel Supply Line to the engine for a kink or restriction.
Is the line kinked or restricted?All
Ye s®Release the fuel pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 14
14 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Adjust a shop air hose to 40 psi.
Remove the Fuel Filter.
Using shop air, inspect the Fuel Filter passage by attempting to blow air through
inlet.
Is the Fuel Filter restricted?All
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Replace the Fuel Pump and Regulator Assembly.
Perform Powertrain Verification Test VER-2A.
15 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve the Fuel Pressure.
Tee-in Fuel Pressure Gauge into the Fuel Supply Hose using Tool #6433.
Turn Ignition On.
With the DRB, actuate the ASD Fuel System test.
Record the Fuel Pressure reading.
Is the Fuel Pressure above 53 psi?ENGINE - 3.0L V6
Ye s®Go To 16
No®Go To 18
16 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Remove the Fuel Return Line between the Fuel Tank and Filter.
Adjust a shop air hose to 40 psi.
Using shop air, inspect the Fuel Line by attempting to blow air through it.
Is the Fuel Return Line restricted?All
Ye s®Replace the Fuel Return Line.
Perform Powertrain Verification Test VER-2A.
No®Go To 17
17 If there are no potential causes remaining, the Fuel Pressure Regulator is assumed
to be defective.
View repair options.All
Repair
Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-2A.
240
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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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.
241
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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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
279
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
280
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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