air condition CHRYSLER VOYAGER 2000 Diagnostic Manual

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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TEST ACTION APPLICABILITY
8 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.All
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-1A.
9 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 10
No®Repair Park/Neutral Switch.
Perform Powertrain Verification Test VER-1A.
10 Ignition Off
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Warning: The Engine may be cranked in the next step. Keep away from
moving parts.
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 Solenoid click when the jumper wire was connected?All
Ye s®Go To 11
No®Go To 15
11 Ignition Off
Check the Battery Cables for high resistance. (Use Service Manual procedure.)
Did either Battery Circuit have a voltage drop greater than 0.2 volt?All
Ye s®Repair the Battery Circuit for high resistance.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
12 Ignition Off
Attempt to manually rotate the Crankshaft 360 degrees.
Is the Crankshaft able to rotate 360 degrees?All
Ye s®Go To 13
No®Repair the Engine mechanical problem as necessary.
Perform Powertrain Verification Test VER-1A.
13 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 14
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
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* NO CRANK CONDITION ÐContinued
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TEST ACTION APPLICABILITY
14 Ignition Off.
Disconnect Starter Relay Output Wire from the Starter Solenoid.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure Starter Relay Output Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 19
No®Repair open Starter Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
15 Ignition Off
Check the Battery Cables for high resistance. (Use Service Manual procedure.)
Did either Battery Circuit have a voltage drop greater than 0.2 volt?All
Ye s®Repair the Battery Circuit for high resistance.
Perform Powertrain Verification Test VER-1A.
No®Go To 16
16 Ignition Off
Attempt to manually rotate the Crankshaft 360 degrees.
Is the Crankshaft able to rotate 360 degrees?All
Ye s®Go To 17
No®Repair the Engine mechanical problem as necessary.
Perform Powertrain Verification Test VER-1A.
17 Ignition Off.
Disconnect Starter Relay Output Wire from the Starter Solenoid.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure Starter Relay Output Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 18
No®Repair open Starter Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
18 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 19
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
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* NO CRANK CONDITION ÐContinued
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TEST ACTION APPLICABILITY
19 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 20
No®Repair the open Ignition Switch Output (Start) Circuit.
Perform Powertrain Verification Test VER-1A.
20 If there are no potential causes remaining, the Starter Motor is assumed to be
defective.
View repair options.All
Repair
Replace the Starter Motor.
Perform Powertrain Verification Test VER-1A.
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STARTING
* NO CRANK CONDITION ÐContinued
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Symptom:
* START AND STALL CONDITION
TEST ACTION APPLICABILITY
1Note: Ensure the SKIM has proper communication and that there are no
SKIM DTC's present before continuing.
At this point in the diagnostic test procedure, it is assumed that all of the engine
electrical systems are operating as designed and are not the cause of a start and stall,
or a no start problem.
The following additional items should be checked as possible mechanical problems.
Any one of these items can produce a start and stall, or no start condition; none can
be overlooked as a possible cause.
1. ENGINE VALVE TIMING - must be within specifications
2. ENGINE COMPRESSION - must be within specifications
3. ENGINE EXHAUST SYSTEM - must be free of any restrictions
4. ENGINE PCV SYSTEM - must flow freely
5. FUEL - must be free of contamination
6. ENGINE SECONDARY IGNITION CHECK - must exhibit a normal scope pattern
7. THROTTLE BODY - must be free of any coking conditions.
8. IDLE AIR CONTROL MOTOR - passages must be free of any debris or carbon.
Always look for any Technical Service Bulletins that may relate to this condition.All
Test Complete.
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Symptom:
P-0740 TORQUE CONV CLUTCH, NO RPM DROP AT LOCKUP
When Monitored and Set Condition:
P-0740 TORQUE CONV CLUTCH, NO RPM DROP AT LOCKUP
When Monitored: Continuously when no matured or maturing Trouble Code and throttle
position >10% and constant for 4.4 seconds before TCC engagement requested: No TCC
solenoid circuit, any cam/crank-related code, VSS, any TPS-related code and Battery
voltage >11.0
Set Condition: Torque Converter malfunctions that are detected are the FTC not locking
up properly when desired, and the torque converter not unlocking properly when desired.
3 consecutive test failures over one trip will store the code. 2 bad trips will set the code.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
DIFF, SHAFT, OR GEARS DEFECTIVE
TCC SOL DEFECTIVE
TORQUE CONVERTER ASSEMBLY DEF OR TCC SOL STUCK
TRANSMISSION FLUID DIRTY OR LEVEL LOW
VEHICLE CONFIGURATION NON-STANDARD
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 2
No®Test Complete.
2 Ignition Off
At the9Cooler In9port puta0to300PSIgauge using a9T9. Ensure line is long
enough to reach in driver's side of vehicle so gauge can be monitored while driving.
Road test vehicle. Gear select in drive. While monitoring DRB, achieve 50 MPH.
While doing this, notice the gauge will read around 15 PSI until lockup is achieved
in 3rd gear. If the TCC Solenoid is operating properly, the gauge pressure will
fluctuate when lockup is achieved.
Did gauge fluctuate?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 3
No®Refer to service instructions for proper service procedure on
Torque Converter Assembly or stuck TCC Solenoid and repair as
necessary.
Perform Powertrain Verification Test VER-5A.
302
TRANSMISSION
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Symptom:
P-0743 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0743 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT
When Monitored: With the ignition key on.
Set Condition: An open or shorted condition is detected in the Torque Converter Clutch
Solenoid Control Circuit.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
TORQUE CONVERTER CLUTCH SOLENOID DEFECTIVE
TCC SOLENOID CIRCUIT W/H INTERMITTENT DEFECT
TCC SOLENOID CIRCUIT W/H OBSERVABLE DEFECT
TCC SOLENOID CONTROL CIRCUIT OPEN
TCC SOLENOID CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE (TCC SOLENOID CONTROL CIRCUIT)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Disconnect the TCC Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Key on.
With the Voltmeter, probe the voltage of the Fused Ignition Switch Output Circuit at
Solenoid Connector.
Is the voltage above 10.0 volts?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 3
No®Repair the open Fused Ignition Switch Output Circuit..
Perform Powertrain Verification Test VER-5A.
304
TRANSMISSION
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Symptom:
P-1899 PARK/NEUTRAL SWITCH STUCK IN PARK OR IN GEAR
When Monitored and Set Condition:
P-1899 PARK/NEUTRAL SWITCH STUCK IN PARK OR IN GEAR
When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in
mode.
Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state
for a given mode of vehicle operation in two consecutive failures.
POSSIBLE CAUSES
P/N SWITCH SENSE CIRCUIT OPEN
PARK/NEUTRAL SWITCH SENSE CIRCUIT OPEN
PARK/NEUTRAL SWITCH SENSE CIRCUIT SHORT TO GROUND
PARK/NEUTRAL SWITCH SENSE CIRCUIT SHORT TO GROUND
PARK/NEUTRAL SWITCH WIRING HARNESS OBSERVABLE DEFECT
PARK/NEUTRAL SWITCH WIRING HARNESS OBSERVABLE DEFECT
PARK/NEUTRAL SWITCH DEFECTIVE
TRS DEFECTIVE
PCM DEF (P/N SWITCH)
PCM DEF (P/N SWITCH)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running.
With the DRB, read Park/Neutral Switch input state.
While moving gear selector in and out of Park and Reverse, watch DRB Display.
Did the display show9P/N and D/R9?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 2
No®Go To 3
2 Ignition Off.
Inspect the Wiring and Connector relating to Park/Neutral Position Switch.
Were any problems found?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
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TRANSMISSION
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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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VERIFICATION TEST VER-5A APPLICABILITY
OBDII Road Test Verification
Use this test to verify that the OBDII symptom has been repaired and that the vehicle can be
returned to the customer. The proper way to verify that an OBDII DTC has been repaired is to
allow the PCM to run and pass the appropriate OBDII monitor(s).
Note: If the Powertrain Control Module has been changed 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. If any other DTC is present, refer to the symptom list for further diagnostic testing
procedures.
3. With the DRBIIIt, Clear DTC's.
4. In order for an OBDII monitor to run, certain pre-test conditions must be met. Refer to the
applicable OBDII monitor pre-test screen on the DRBIIItfor monitor enabling conditions.
5. Operate the vehicle within the enabling conditions and allow the applicable monitor to run.
While the monitor is running, the OBDII monitor screen on the DRBIIItwill display ªIN
PROGRESSº and the DRBIIItwill beep. After the monitor is complete, view the results. Refer
to the appropriate service information as necessary. A monitor may have to fail more than once
in order to set a DTC.
If the monitor fails, or the DTC returns, 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.
If there are no DTC's present and all components are functioning properly, the repair is
complete.ALL
Powertrain Verification Test VER-5A2 APPLICABILITY
Fuel System Lean/Rich or Misfire Verification
Use this test to verify that the Fuel System Lean, Fuel System Rich, or Misfire 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 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. If any other DTC is present, refer to the symptom list for further diagnostic testing
procedures.
3. With the DRBIIIt, monitor the Similar Conditions Window and attempt to duplicate the
conditions that the vehicle was operating at when the DTC was set. If the conditions can be
duplicated, the Good Trip counter will change to one or more.
4. If the DTC resets, or the OBDII monitor fails after running, or if any other symptom or DTC
is present, return to the symptom list and perform the appropriate diagnostic testing
procedures. Check for any Technical Service Bulletins that may apply.
5. If the monitor runs and the Good Trip Counter changes to one or more, the condition is no
longer present. If there are no DTCs and all components are functioning properly, the repair is
complete.ALL
320
VERIFICATION TESTS
Verification Tests ÐContinued
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