CHRYSLER VOYAGER 2000 Diagnostic Manual

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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DRIVEABILITY
P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
13 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Evap Purge Solenoid Control Circuit at Connector
to ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the Proportional Purge Solenoid Control Circuit short to
ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 14
14 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using and Ohmmeter, measure the Proportional Purge Solenoid Control Circuit
PCM to Solenoid Connector.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 15
No®Repair the open PPS Control Circuit.
Perform Powertrain Verification Test VER-5A.
15 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the PWM Purge Sense Circuit to ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the PWM Purge Sense Circuit short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 16
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DRIVEABILITY
P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
16 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using and Ohmmeter, measure the PWM Purge Sense Circuit PCM to Solenoid
Connector.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 17
No®Repair the open PWM Purge Sense Circuit.
Perform Powertrain Verification Test VER-5A.
17 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-5A.
18 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
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 19
19 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 20
20 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.
147
DRIVEABILITY
P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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Symptom:
P-0460 FUEL LEVEL UNIT NO CHANGE OVER MILES
POSSIBLE CAUSES
FUEL LEVEL SENSOR WIRING/HARNESS OBSERVABLE DEFECT
FUEL TANK OBSTRUCTED
TEST COMPLETE
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, read the Fuel Level Sensor voltage and make a note of the voltage.
Add two gallons of fuel to the Fuel Tank.
With the DRB, read the Fuel Level Sensor voltage.
Did the Fuel Level Sensor voltage decrease by at least 0.2 volts?All
Ye s®Go To 2
No®Check for an obstruction in the Fuel Tank. If ok replace Fuel
Level Sensor.
Perform Powertrain Verification Test VER-2A.
2 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
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
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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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DRIVEABILITY
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TEST ACTION APPLICABILITY
5 Ignition On
Use the schematic as a guide and wiggle the Connector & Harness.
Using the DRB, monitor the Fuel Level Sensor voltage.
Was there any Fuel Level Sensor Voltage change?All
Ye s®Repair the Harness or Connector that caused the voltage change.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 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
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
P-0462 FUEL LEVEL SENDING UNIT VOLTS TOO LOW ÐContinued
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Symptom:
P-0463 FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
POSSIBLE CAUSES
FUEL LEVEL SENSOR DEFECTIVE
FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN
FUEL PUMP MODULE WIRING/HARNESS INTERMITENT DEFECT
BODY CONTROL MODULE DEFECTIVE
FUEL PUMP MODULE OBSERVABLE DEFECT
FUEL PUMP MODULE GROUND CIRCUIT DEFECTIVE
TEST COMPLETE
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, read the DTC's.
Is the Global Good Trip counter dispalyed and equal to zero?All
Ye s®Go To 2
No®Go To 6
2 Key Off
Disconnect the Fuel Pump Module Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper between the Fuel Level Sensor Signal Circuit and the Ground
Circuit at the Fuel Pump Module Connector.
With the DRB, read the Fuel Level Sensor voltage.
Is the voltage below 1.0 volt?All
Ye s®Replace the Fuel Level Sensor.
Perform Powertrain Verification Test VER-2A.
No®Go To 3
3 Key Off
Disconnect the Fuel Pump Module Connector.
Note: Check connectors - Clean/repair as necessary.
Measure resistance of the Ground Circuit at the Fuel Pump Module Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the Ground Circuit as necessary.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Key Off
Disconnect the Fuel Pump Module Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Body Control Module9B9(GREY) Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Fuel Level Sensor Signal Circuit from the BCM to
the Fuel Pump Module Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open Fuel Level Sensor Signal Circuit.
Perform Powertrain Verification Test VER-2A.
5 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.
6 Ignition On
Using the schematic as a guide, wiggle the Fuel Pump Module Connector and
Harness.
Using the DRB, monitor the Fuel Level Sensor voltage.
Was there any Fuel Level Sensor voltage change?All
Ye s®Repair the Harness or Connector that caused the voltage change.
Perform Powertrain Verification Test VER-2A.
No®Go To 7
7 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.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
P-0463 FUEL LEVEL SENDING UNIT VOLTS TOO HIGH ÐContinued
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Symptom:
P-0500 NO VEHICLE SPEED SENSOR SIGNAL
When Monitored and Set Condition:
P-0500 NO VEHICLE SPEED SENSOR SIGNAL
When Monitored: For 3 Speed: With engine running, transmission not in park or neutral,
brakes not applied, engine rpm greater than 1500. For 4 Speed: With the engine running,
transmission not in park or neutral, brakes not applied, engine rpm greater than 1500.
Set Condition: For 3 Speed: No signal from the vehicle speed sensor for more than 11
seconds for 2 consecutive trips. For 4 Speed: No signal from the vehicle speed sensor (TCM)
is present for more than 11 seconds for 2 consecutive trips.
POSSIBLE CAUSES
ELECTRONIC AUTO TRANSAXLE TROUBLE CODES PRESENT
8-VOLT SUPPLY CIRCUIT OPEN
PCM DEF (NO VSS SIGNAL CKT)
PCM TERMINAL DEFECTIVE
VEHICLE SPEED SENSOR GROUND CIRCUIT OPEN
VEHICLE SPEED SENSOR SIGNAL CIRCUIT WIRING HARNESS OBSERVABLE DEFECT
PINION GEAR DEFECTIVE
OUTPUT SPEED SENSOR CIRCUIT OPEN
OUTPUT SPEED SENSOR CIRCUIT SHORTED TO GROUND
VEHICLE SPEED SENSOR SIGNAL CIRCUIT OPEN
VSS SIGNAL CIRCUIT SHORTED TO GROUND
OUTPUT SPEED SENSOR DEFECTIVE
OUTPUT SPEED SENSOR DEFECTIVE (RES > 5.0)
PCM DEFECTIVE (NO VSS SIGNAL CKT)
PCM DEFECTIVE (NO VSS SIGNAL CKT)
TCM DEFECTIVE (VSS SIG CKT)
VSS DEFECTIVE
153
DRIVEABILITY
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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
154
DRIVEABILITY
P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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