engine CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
18 Ignition Off
Disconnect the Transmission Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance between the Output Speed Sensor
Circuit at the TCM Connector and Ground.
Is the resistance below 5.0 ohms?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 19
No®Go To 21
19 Ignition off.
Disconnect the Transmission Control Module.
Disconnect the Output Speed Sensor.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance between the Output Speed Sensor
Circuit at the TCM Connector and Ground.
Is the resistance below 5.0 ohms?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 the Output Speed Sensor Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 20
20 If there are no potential causes remaining, the Output Speed Sensor is assumed to be
defective.
View repair options.ENGINE - 2.0L,
2.4L, 3.3L V6 FFV
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
w/EATX
Repair
Replace the Output Speed Sensor.
Perform Powertrain Verification Test VER-5A.
21 Ignition Off
Disconnect theTransmission Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure between the Speed Sensor Ground Circuit and the
Output Speed Sensor Circuit at the TCM Connector..
Is the resistance between 300.0 and 1200.0 ohms?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®Replace the Transmission Control Module, reprogram Pinion
Factor, and perform quick learn procedure.
Perform Powertrain Verification Test VER-5A.
No®Go To 22
22 Ignition Off
Disconnect the Transmission Control Circuit.
Disconnect the Output Speed Sensor.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Speed Sensor Ground Circuit from the TCM to the
Output Speed Sensor.
Is the resistance under 5.0 ohms?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 23
No®Repair the open Speed Sensor Ground Circuit.
Perform Powertrain Verification Test VER-5A.
157
DRIVEABILITY
P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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TEST ACTION APPLICABILITY
23 Ignition off.
Disconnect the Transmission Control Module.
Disconnect the Output Speed Sensor.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Output Speed Sensor (OSS) from the TCM to the
OSS.
Is the resistance under 5.0 ohms?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 24
No®Repair the open Output Speed Sensor Circuit.
Perform Powertrain Verification Test VER-5A.
24 If there are no potential causes remaining, the Output Speed Sensor is assumed to be
defective.
View repair options.ENGINE - 2.0L,
2.4L, 3.3L V6 FFV
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
w/EATX
Repair
Replace the Output Speed Sensor.
Perform Powertrain Verification Test VER-5A.
25 Ignition Off
Disconnect the Transmission Control Module.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure between the VSS Signal Circuit and ground.
Is the resistance below 5.0 ohms?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 the Vehicle Speed Sensor Signal Circuit for a short to
ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 26
26 Ignition off.
Disconnect the Transmission Control Module.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the VSS Signal Circuit from the PCM to the TCM.
Is the resistance below 5.0 ohms?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 27
No®Repair the open Vehicle Speed Sensor Signal Circuit.
Perform Powertrain Verification Test VER-5A.
27 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ENGINE - 2.0L,
2.4L, 3.3L V6 FFV
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
w/EATX
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
158
DRIVEABILITY
P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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Symptom:
P-0505 IDLE AIR CONTROL MOTOR CIRCUITS
When Monitored and Set Condition:
P-0505 IDLE AIR CONTROL MOTOR CIRCUITS
When Monitored: At key on and battery voltage greater than 11.5 volts.
Set Condition: The PCM senses a short to ground or battery voltage on any of the four
IAC driver circuits for 2.75 seconds while the IAC motor is active.
POSSIBLE CAUSES
IAC #4 DRIVER CIRCUIT SHORTED TO GROUND
IDLE AIR CONTROL MOTOR DEFECTIVE
POWERTRAIN CTRL MODULE CONNECTOR OBSERVABLE DEFECT
IAC #1 DRIVER CIRCUIT SHORTED TO #2, #3, OR #4
IAC #1 DRIVER CIRCUIT SHORTED TO GROUND
IAC #2 DRIVER CIRCUIT SHORTED TO #3 OR #4
IAC #2 DRIVER CIRCUIT SHORTED TO GROUND
IAC #3 DRIVER CIRCUIT SHORTED TO #4
IAC #3 DRIVER CIRCUIT SHORTED TO GROUND
IAC MOTOR WIRING HARNESS INTERMITTENT DEFECT
IAC MOTOR WIRING HARNESS OBSERVABLE DEFECT
TEST ACTION APPLICABILITY
1 Turn ignition off for 10 seconds, then start engine and let idle.
Allow engine to reach normal operating temperature.
With the DRB in actuators, set RPM to 1400.
Is the engine speed 1400 +/- 100 RPM?All
Ye s®Go To 2
No®Go To 6
2 Turn ignition off for 10 seconds, then start engine and let idle.
Allow engine to reach normal operating temperature.
With the DRB in actuators, set RPM to 900.
Is the engine speed 900 +/- 100 RPM?All
Ye s®Go To 3
No®Go To 6
159
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Turn ignition off for 10 seconds, then start engine and let idle.
Allow engine to reach normal operating temperature.
With the DRB in Systems Test, perform the IAC Wiggle Test.
Note: The idle speed should raise and lower with the display.
Does the IAC Motor operate properly?All
Ye s®Go To 4
No®Go To 6
4 Turn ignition off for 10 seconds, then start engine and let idle. Allow engine to reach
normal operating temperature.
With the DRB in Systems Test, perform the IAC Wiggle Test.
Note: The idle speed should raise and lower with the display.
Wiggle the Wiring Harness from the IAC Motor to the PCM.
Observe for the IAC Motor to stop operating.
Did the IAC Motor stop operating at any time?All
Ye s®Repair the Harness or Connectors as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 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®Test Complete.
6 Start engine and let idle.
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure the IAC Driver #1 Circuit.
Was the voltage over 5.0 volts at any time?All
Ye s®Go To 7
No®Refer to symptom P-0505B IDLE AIR CONTROL MOTOR CIR-
CUIT in the DRIVEABILITY category.
7 Ignition Off
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure between IAC #4 Driver and ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the IAC #4 Driver Circuit shorted to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
160
DRIVEABILITY
P-0505 IDLE AIR CONTROL MOTOR CIRCUITS ÐContinued
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TEST ACTION APPLICABILITY
8 Start engine and let idle.
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure the IAC Driver #2 Circuit.
Was the voltage over 5.0 volts at any time?All
Ye s®Go To 9
No®Refer to symptom P-0505C IDLE AIR CONTROL MOTOR CIR-
CUIT in the DRIVEABILITY category.
9 Ignition Off
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure between IAC #1 Driver and ground..
Is the resistance below 5.0 ohms?All
Ye s®Repair the IAC #1 Driver Circuit shorted to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 10
10 Ignition Off
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure between IAC #2 Driver and ground..
Is the resistance below 5.0 ohms?All
Ye s®Repair the IAC #2 Driver Circuit shorted to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 11
11 Start engine and let idle.
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure the IAC Driver #3 Circuit.
Was the voltage over 5.0 volts at any time?All
Ye s®Go To 12
No®Refer to symptom P-0505D IDLE AIR CONTROL MOTOR CIR-
CUIT in the DRIVEABILITY category.
12 Ignition Off
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure between IAC #3 Driver and ground..
Is the resistance below 5.0 ohms?All
Ye s®Repair the IAC #3 Driver Circuit shorted to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 13
161
DRIVEABILITY
P-0505 IDLE AIR CONTROL MOTOR CIRCUITS ÐContinued
ProCarManuals.com

TEST ACTION APPLICABILITY
13 Start engine and let idle.
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure the IAC Driver #4 Circuit.
Was the voltage over 5.0 volts at any time?All
Ye s®Go To 14
No®Refer to symptom P-0505E IDLE AIR CONTROL MOTOR CIR-
CUIT in the DRIVEABILITY category.
14 Ignition Off
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Is any Terminal damaged, pushed out or miswired?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 15
15 Ignition Off
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance between the IAC #1 Driver and #2, #3,
#4 Drivers.
Is the resistance below 5.0 ohms on any of the Drivers?All
Ye s®Repair the IAC Driver Circuits shorted together.
Perform Powertrain Verification Test VER-5A.
No®Go To 16
16 Ignition Off
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance between the IAC #2 Driver and #3, #4
Drivers.
Is the resistance below 5.0 ohms on any of the Drivers?All
Ye s®Repair the IAC Driver Circuits shorted together.
Perform Powertrain Verification Test VER-5A.
No®Go To 17
17 Ignition Off
Disconnect the IAC Motor Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance between the IAC #3 Driver and #4
Driver.
Is the resistance below 5.0 ohms?All
Ye s®Repair the IAC Driver Circuits shorted together.
Perform Powertrain Verification Test VER-5A.
No®Go To 18
162
DRIVEABILITY
P-0505 IDLE AIR CONTROL MOTOR CIRCUITS ÐContinued
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Symptom:
P-0600 PCM FAILURE SPI COMMUNICATIONS
When Monitored and Set Condition:
P-0600 PCM FAILURE SPI COMMUNICATIONS
When Monitored: With the ignition key on.
Set Condition: Internal Bus Communication failure between processors.
POSSIBLE CAUSES
PCM FAILURE SPI COMMUNICATIONS
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running.
With the DRB, read Trouble Codes.
Is Trouble Code PCM FAILURE SPI COMMUNICATION present?All
Ye s®Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-2A
No®Test Complete.
168
DRIVEABILITY
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Symptom:
P-0601 INTERNAL CONTROLLER FAILURE
When Monitored and Set Condition:
P-0601 INTERNAL CONTROLLER FAILURE
When Monitored: With the ignition key on.
Set Condition: Internal checksum for software failed, does not match calculated value.
POSSIBLE CAUSES
INTERNAL CONTROLLER FAILURE
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running.
With the DRB, read Trouble Codes.
Is Trouble Code INTERNAL CONTROLLER FAILURE present?All
Ye s®Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-2A
No®Test Complete.
169
DRIVEABILITY
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Symptom:
P-0645 A/C CLUTCH RELAY CIRCUIT
When Monitored and Set Condition:
P-0645 A/C CLUTCH RELAY CIRCUIT
When Monitored: With the ignition key on and battery voltage greater than 10 volts.
Set Condition: An open or shorted condition is detected in the A/C clutch relay control
circuit.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
AIR CONDITIONING CLUTCH RELAY DEFECTIVE
A/C CLUTCH RELAY CIRCUIT WITHOUT INTER DEFECT
A/C CLUTCH RELAY CIRCUIT WITHOUT OBSER DEFECT
A/C CLUTCH RELAY CONTROL CIRCUIT SHORT TO GROUND
AIR CONDITIONING CLUTCH RELAY CONTROL CIRCUIT OPEN
PCM DEF (A/C CLUTCH RELAY)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
Actuate the Air Conditioning Clutch Relay.
Is the Air Conditioning Clutch Relay clicking?All
Ye s®Go To 2
No®Go To 4
2 Ignition On, Engine Not Running
Actuate the Air Conditioning Clutch Relay.
Wiggle the Wiring Harness from the Relay to the PCM.
Did the wiggling interrupt the clicking?All
Ye s®Repair as necessary where wiggling caused the clicking to be
interrupted.
Perform Powertrain Verification Test VER-2A.
No®Go To 3
3 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-2A.
No®Test Complete.
170
DRIVEABILITY
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Symptom:
P-0703 BRAKE SWITCH STUCK PRESSED OR RELEASED
When Monitored and Set Condition:
P-0703 BRAKE SWITCH STUCK PRESSED OR RELEASED
When Monitored: With engine running. The PCM expects the signal to be high for 16
cycles while it monitors the brake switch signal during accel and decel modes.
Set Condition: After the vehicle speed increases, the PCM must accumulate 6 seconds
while delta throttle voltage is above 0.02 volt. The count is reset to zero whenever the
brake switch indicates a low signal.
POSSIBLE CAUSES
BRAKE SWITCH GROUND CIRCUIT OPEN
BRAKE SWITCH INTERNAL SHORT
BRAKE SWITCH SENSE CIRCUIT OPEN
BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND
PCM CONNECTOR OBSERVABLE DEFECT
PCM DEF (VOLTAGE HIGH)
PCM DEF (VOLTAGE LOW)
TEST ACTION APPLICABILITY
1 Ignition Off
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
Key on.
With a Voltmeter, measure the Brake Switch Sense Circuit at the Brake Switch
Connector.
Is the voltage above 9.0 volts?All
Ye s®Go To 2
No®Go To 5
2 Ignition Off
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Brake Switch Ground Circuit at the Brake Switch
Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Repair the Brake Switch Ground Circuit.
Perform Powertrain Verification Test VER-2A.
172
DRIVEABILITY
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