display CHRYSLER VOYAGER 2000 Diagnostic Manual

Symptom:
P-0401 EGR SYSTEM FAILURE
When Monitored and Set Condition:
P-0401 EGR SYSTEM FAILURE
When Monitored: With engine temp > than 82 degrees C (180 degrees F), ambient temp
> 4 degrees C (40 degrees F), engine in closed loop, O2 Sensor operational, engine under a
steady load with throttle open, and O2 Controller not at or near its limits.
Set Condition: If all conditions met, turn EGR off & on. O2 Snsr Sig is monitored for
change in output sig. If no major change or too much change, flag is set. Repeat test up to
3x in run cycle (2 trips). If fails every time, code sets. If any pass, diags are suspended.
POSSIBLE CAUSES
EXHAUST LEAK
INTAKE MANIFOLD RESTRICTED
EGR BACK PRESSURE TRANSDUCER DEFECTIVE
EGR VALVE ASSEMBLY DEFECTIVE
EGR VALVE ASSEMBLY MOUNTED INCORRECTLY
EGR SYSTEM FAILURE DOES NOT REOCCUR
EGR TRANSDUCER LINE BLOCKED
EGR VALVE ASSEMBLY DIAPHRAM DEFECTIVE
VACUUM SUPPLY TO EGR SOLENOID INADEQUATE
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the EGR System Failure does not exist or is an intermittent problem.
With the DRB, read the FREEZE FRAME.
With this screen, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME, pay particular attention to the fault setting condi-
tions, such as speed, temp, load, and map vacuum.
Does the EGR System Failure reoccur?All
Ye s®Go To 3
No®EGR System Failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
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Symptom:
P-0403 EGR SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0403 EGR SOLENOID CIRCUIT
When Monitored: With the ignition key on and engine running and battery voltage > 10
volts.
Set Condition: The EGR solenoid control circuit is not in the expected state when
requested to operate by the PCM.
POSSIBLE CAUSES
EGR SOLENOID DEFECTIVE
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EGR SOLENOID CIRCUIT WIRING HARNESS INTER DEFECT
EGR SOLENOID CIRCUIT WIRING HARNESS OBSERVABLE DEF
EGR SOLENOID CONTROL CIRCUIT OPEN
EGR SOLENOID CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE (EGR SOL CKT)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the codes.
Is the Global Good Trip displayed and equal to 0?All
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Turn ignition on with engine not running.
Using the DRB, actuate the EGR Solenoid.
Using a Voltmeter, probe the Fused Ignition Switch Output Circuit at the EGR
Solenoid Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 3
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-2A.
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Symptom:
P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored and Set Condition:
P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored: After engine warm up to 63 degrees C (147 degrees F), 180 seconds of
open throttle operation, at a speed greater than 30 Km/h (20 mph), with the engine at
1200-1700 rpm and MAP vacuum between 15.0 and 21.0 inches of mercury (Hg).
Set Condition: As catalyst efficiency deteriorates, the switch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. If at any point during the test the
switch ratio reaches a predetermined value a counter is incremented by one.
POSSIBLE CAUSES
EXHAUST LEAK
ENGINE MECHANICAL PROBLEM
CATALYTIC CONVERTER DEFECTIVE
UPSTREAM O2 SENSOR OLDER THAN DOWNSTREAM O2 SENSOR
CATALYST EFFICIENCY FAILURE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIPS counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the Catalyst Efficiency Failure does not exist or is an intermittent
problem.
With the DRB, read the FREEZE FRAME DATA.
With this screen, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME DATA pay particular attention to the fault setting
conditions, such as speed, temp, load, and map vacuum.
Does the Catalyst Efficiency Failure Reoccur?All
Ye s®Go To 3
No®The Catalytic Conveter Efficiency Failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
3 Start Engine and let idle.
Check for exhaust leaks between the Engine and the appropriate Downstream O2
Sensor.
Are there any exhaust leaks?All
Ye s®Repair or replace leaking exhaust parts as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Go To 4
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Symptom:
P-0441 EVAP PURGE FLOW MONITOR FAILURE
When Monitored and Set Condition:
P-0441 EVAP PURGE FLOW MONITOR FAILURE
When Monitored: With engine temperature greater than 170ÉF, engine in closed loop,
engine idling for 2 minutes, no low fuel, MAP less than 15.7 inches mercury, and
barometric altitude less than 8,000 feet.
Set Condition: Note: with LDP: must pass stricter evap system test first. No air flow
through the evaporative system is detected by the evap monitor.
POSSIBLE CAUSES
PURGE CANISTER LINE DAMAGED
PURGE SOLENOID AND CANISTER DEFECTIVE
PURGE SOLENOID DEFECTIVE
VACUUM HOSES DAMAGED OR PLUGGED
EVAP PURGE MONITOR FAILURE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the Evap Purge Flow Monitor Failure does not exist or is an intermittent
problem.
With the DRB, read the FREEZE FRAME DATA.
With these screens, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME pay particular attention to the fault setting condi-
tions, such as speed, temp, load, and map vacuum.
Does the Evap Purge Flow Monitor Failure reoccur?All
Ye s®Go To 3
No®The Evap Purge Flow Monitor failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
3NOTE: Carefully inspect all vacuum hoses for proper routing and for
pinched or plugged hoses from the engine to the solenoid to the gas tank.
Are all vacuum hoses OK?All
Ye s®Go To 4
No®Repair the vacuum hoses as necessary.
Perform VERIFICATION TEST VER-5A3.
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Symptom List:
P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED
P-0455 EVAP LEAK MONITOR LARGE LEAK DETECTED
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P-0442 EVAP LEAK MONITOR
SMALL LEAK DETECTED.
When Monitored and Set Condition:
P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED
When Monitored: See DRB III.
Set Condition: See DRB III.
P-0455 EVAP LEAK MONITOR LARGE LEAK DETECTED
When Monitored: See DRB III.
Set Condition: See DRB III.
POSSIBLE CAUSES
EVAP SYSTEM HOSES OR WIRING DAMAGED
EVAP SYSTEM COMPONENT LEAKING
LEAK DETECTION PUMP LEAKING
EVAP LEAK MONITOR SMALL OR LARGE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1NOTE: Replacing the Powertrain Control Module will not correct this
problem.
With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time, the conditions required to set this DTC are not present.
With the DRB, perform the LDP Monitor Test.
Follow the instructions on the DRB and allow the PCM to run the monitor.
After the monitor has finished running, does the DRB show ªTEST FAILED THIS
TRIP : YES'' on the monitor screen?All
Ye s®Go To 3
No®The Evap Leak Monitor DTC is not present at this time.
Perform VERIFICATION TEST VER-6A.
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Symptom:
P-0443 EVAP PURGE SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0443 EVAP PURGE SOLENOID CIRCUIT
When Monitored: With the ignition key on and the engine running.
Set Condition: After arming conditions are satisfied: not powering down, not already in
limp-in, time since last solenoid activation > 72 micro seconds. The PCM will set a trouble
code if the actual sate of the solenoid does not match the intended state.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
PROPORTIONAL EVAP PURGE SOLENOID DEFECTIVE
EVAP PURGE SOL CKT WIRING HARNESS INTERMITTENT DEF
EVAP PURGE SOLENOID CKT WIRING HARNESS OBS DEFECT
EVAP PURGE SOLENOID CONTROL CIRCUIT OPEN
EVAP PURGE SOLENOID CONTROL CIRCUIT SHORT TO GND
PROPORTIONAL PURGE SOL CONTROL CKT SHORT TO GROUND
PROPORTIONAL PURGE SOLENOID CONTROL CIRCUIT OPEN
PWM PURGE SENSE CIRCUIT OPEN
PWM PURGE SENSE CIRCUIT SHORT TO GROUND
POWERTRAIN CONTROL MODULE DEFECTIVE
TEST ACTION APPLICABILITY
1 Is the vehicle equipped with a Proportional Purge solenoid? ALL
Ye s®Go To 10
No®Go To 2
2 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?ALL
Ye s®Go To 3
No®Go To 8
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TEST ACTION APPLICABILITY
8 Ignition On, Engine Not Running.
With the DRB, read codes.
With the DRB, actuate the Evap Purge Solenoid.
Wiggle Wiring Harness from the Solenoid to PCM.
Does the Evap Purge Solenoid Control Circuit code return?ALL
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 9
9 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-5A.
No®Go To 10
10 Check the freeze frame data to determine the conditions when code was set.
Attempt duplication of 'freeze frame' conditions for added diagnostics.
If there are no other possible causes remaining there is assumed to be an9intermit-
tent9problem with a Wiring Harness Connector or Wire.
View repair options.ALL
Repair
Visually inspect related Wire Harness Connectors and Harnesses.
Look for broken, bent, pushed out, or corroded terminals and for
chafed, pierced, or partiallly broken wire, respectively. Refer to
any hotlines or technical service bulletins that apply.
11 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?ALL
Ye s®Go To 12
No®Go To 18
12 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the Proportional Purge Solenoid.
Is the resistance 14.2 ohms +/- 1.4?ALL
Ye s®Go To 13
No®Replace the open Proportional Purge Solenoid.
Perform Powertrain Verification Test VER-5A.
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P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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Symptom:
P-0462 FUEL LEVEL SENDING UNIT VOLTS TOO LOW
POSSIBLE CAUSES
FUEL LEVEL SENSOR DEFECTIVE
FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FUEL LEVEL SENSOR WIRING/HARNESS INTERMITENT DEFECT
BODY CONTROL MODULE DEFECTIVE
FUEL LEVEL SENSOR WIRING/HARNESS OBSERVABLE DEFECT
TEST COMPLETE
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, read the DTC's.
is the Global Good Trip counter displayed and equal to zero?All
Ye s®Go To 2
No®Go To 5
2 Ignition Off
Disconnect the Fuel Pump Module Harness Connector.
Note: Check connectors - Clean/repair as necessary.
With the DRB, read the Fuel Level Sensor voltage.
Is the Fuel Level Sensor voltage above 4.5 volts?All
Ye s®Replace the Fuel Level Sensor.
Perform Powertrain Verification Test VER-2A.
No®Go To 3
3 Key Off
Disconnect the Body Control Module9B9(GREY) Connector.
Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Fuel Level Sensor Signal Circuit for resistance to
ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Fuel Level Sensor Signal Circuit shorted to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 If there are no potential causes remaining, the BCM is assumed to be defective.
View repair options.All
Repair
Replace the Body Control Module.
Perform Powertrain Verification Test VER-2A.
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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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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
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P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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