engine CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
27 Start Engine.
At PCM, backprobe CMP Sensor Signal Circuit with Oscilloscope's voltage measure-
ment lead.
While observing the Oscilloscope pattern, wiggle CMP Sensor Circuit from Sensor to
PCM.
Were any signals missing when the wiggle test was conducted?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Note where wiggling the Wires caused a missing CMP Sensor
Signal. Repair Camshaft and Crankshaft Wiring Harness as
necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 28
28 Ignition Off.
At the CKP Sensor, backprobe the CKP Sensor Signal Circuit with the Oscilloscope's
voltage measurement lead.
Start the Engine and observe the CKP Sensor voltage pattern on the Oscilloscope.
Are any Crankshaft Position Sensor Signals missing?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Go To 29
No®Test Complete.
29 Ignition Off.
Disconnect the CKP Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 30
30 Ignition Off.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 31
31 Ignition Off.
Remove the Crankshaft Position (CKP) Sensor.
Inspect the Crankshaft notches for debris or damage.
Are the Crankshaft notches damaged?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair or replace the Crankshaft as necessary.
Perform Powertrain Verification Test VER-5A.
No®Replace the Crankshaft Position Sensor.
Perform Powertrain Verification Test VER-5A.
197
DRIVEABILITY
P-1391 INTERMITTENT LOSS OF CMP OR CKP ÐContinued
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Symptom:
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored and Set Condition:
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored: Under closed throttle decel; A/C off; engine coolant temp > 23 degrees
C (75 degrees F); longer than 50 seconds after engine start. The speed at which the
deceleration occurs must be sufficient for the given gear range, e.g., > 36 Km/h (36 mph)
in first gear or > 104 Km/h (> 65) in high gear.
Set Condition: When one of the CKP Sensor target windows 15 degrees C (60 degrees F)
has more than 2.86% variance from the reference window.
POSSIBLE CAUSES
CKP SENSOR CONNECTOR OBSERVABLE DEFECT
CKP SENSOR CONNECTOR OBSERVABLE DEFECT
CKP SENSOR DEFECTIVE
CKP SENSOR DEFECTIVE
CKP SENSOR NOT PROPERLY INSTALLED
CKP SENSOR NOT PROPERLY INSTALLED
NOTCHES IN CRANKSHAFT DEFECTIVE
SLOTS IN FLEXPLATE DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary.
Perform Verification Test VER-2A.
No®Go To 2
2 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Crankshaft Position Sensor for proper Torque and installation.
Is the Crankshaft Position Sensor properly installed?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 3
No®Properly install CKP Sensor.
Perform Verification Test VER-2A.
198
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off.
Remove the CKP Sensor.
Inspect the Slots in the Flexplate for debris, damage or excessive movement.
Is there any debris, damage or excessive movement?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 If there are no potential causes remaining, the CKP Sensor is assumed to be
defective.
View repair options.ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Repair
Replace the CKP Sensor.
Perform Verification Test VER-2A.
5 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Repair as necessary.
Perform Verification Test VER-2A.
No®Go To 6
6 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Crankshaft Position Sensor for proper Torque and installation.
Is the Crankshaft Position Sensor properly installed?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Go To 7
No®Properly install CKP Sensor.
Perform Verification Test VER-2A.
7 Ignition Off.
Remove the Crankshaft Position Sensor.
Inspect the notches in the Crankshaft for debris, damage or excessive movement.
Is there any debris, damage or excessive movement?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
8 If there are no potential causes remaining, the CKP Sensor is assumed to be
defective.
View repair options.ENGINE -2.0L and
2.4L I-4 DOHC
Repair
Replace the CKP Sensor.
Perform Verification Test VER-2A.
199
DRIVEABILITY
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT ÐContinued
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Symptom:
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored and Set Condition:
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored: Amb temp bet 4 deg C (40deg F) & 32 deg C (90deg F), & coolant w/in
±12 deg C (10deg F) of amb. If PCM suspects pinch, no fault until runs evap purge flow
mon. Purge flow monitored w/eng temp >76 deg C (170deg F), engine in closed loop, idle 2
min, no low fuel, MAP <15.7 in. merc, & baro alt <8000 ft.
Set Condition: LDP must pass stricter evap system test first. No air flow through the
evaporative system is detected by the evap monitor.
POSSIBLE CAUSES
FUEL TANK TO EVAP CANISTER HOSE PINCHED
LDP PRESSURE HOSE BLOCKAGE
PURGE SOLENOID TO EVAP CANISTER HOSE PINCHED
LEAK DETECTION PUMP BLOCKAGE
EVAPORATIVE CANISTER BLOCKAGE LDP SIDE
EVAPORATIVE CANISTER BLOCKAGE SOLENOID SIDE
EVAP LEAK MONITOR PINCHED HOSE 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 Evap Leak Monitor Pinched Hose Found 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 Evap Leak Monitor Pinched Hose Found reoccur?All
Ye s®Go To 3
No®Evap Leak Monitor Pinched Hose Found no longer exists.
Perform VERIFICATION TEST VER-6A.
200
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Remove Vacuum Connector from Purge Solenoid.
Did the pressure drop when the Vacuum Connector was removed?All
Ye s®Go To 4
No®Go To 6
4 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Disconnect Leak Detection Pump Pressure Hose from LDP.
Did pressure drop when hose was disconnected?All
Ye s®Replace the Leak Detection Pump.
Perform VERIFICATION TEST VER-6A.
No®Go To 5
5 Inspect the LDP Pressure Hose.
Is the hose OK?All
Ye s®Replace the Evaporative Canister.
Perform VERIFICATION TEST VER-6A.
No®Replace the LDP Pressure Hose.
Perform VERIFICATION TEST VER-6A.
201
DRIVEABILITY
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND ÐContinued
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TEST ACTION APPLICABILITY
6 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
If disconnected, reconnect the Vacuum Connector at the Purge Solenoid.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Remove hose at Evap Canister that goes to Purge Solenoid.
Did pressure drop when hose was disconnected?All
Ye s®Repair the pinched hose from the Purge Solenoid to the Evap
Canister.
Perform VERIFICATION TEST VER-6A.
No®Go To 7
7 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Remove hose at Evap Canister that goes to Fuel Tank.
Did pressure drop when hose was disconnected?All
Ye s®Replace the Evaporative Canister.
Perform VERIFICATION TEST VER-6A.
No®Repair the pinched hose from the Gas Tank to the Evap Canister.
Perform VERIFICATION TEST VER-6A.
202
DRIVEABILITY
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND ÐContinued
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Symptom:
P-1494 LEAK DETECTION PUMP PRESSURE SWITCH
When Monitored and Set Condition:
P-1494 LEAK DETECTION PUMP PRESSURE SWITCH
When Monitored: Immediately after a cold start, with ambient temperature between 4
deg C (40 deg F) and 32 deg C (90 deg F) and coolant temperature within ±12 deg C (10 deg
F) of ambient temperature.
Set Condition: The state of the switch does not change when the solenoid is energized.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
LDP PRESSURE SWITCH CIRCUIT SHORTED TO GROUND
LDP SWITCH SENSE CIRCUIT OPEN
LDP DEFECTIVE
LDP WIRING HARNESS INTERMITTENT DEFECT
LDP WIRING HARNESS OBSERVABLE DEFECT
LDP VACUUM HOSE LEAKING OR OBSTRUCTED
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Start the engine and allow the engine to idle.
With the DRB, perform the Leak Detect Pump Test.
Select 1 to Pump.
Press the down arrow on the DRB several times.
The LEAK DETECT PUMP SW state should change from Open (UP) to CLOSED
(DN).
Did the Leak Detect Pump Switch state change as described?All
Ye s®Go To 2
No®Go To 4
206
DRIVEABILITY
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TEST ACTION APPLICABILITY
2 Ignition on, engine not running
With the DRB, read DTCs and Freeze Frame Data and record.
With the DRB, Clear DTCs.
Start the engine and allow the engine to idle.
With the DRB, perform the LDP Monitor test.
Wiggle the wiring harness and connectors from the LDP connector to the PCM
connector while the monitor is running.
Note: Be careful of the engine's moving parts.
With the DRB, Read DTCs.
Does the P-1494 Leak Detection Pump Sw or Mechanical Fault DTC return during
the wiggle test?All
Ye s®Repair the wiring harness or connector as necessary.
Perform Powertrain Verification Test VER-5A.
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-5A.
No®Test Complete.
4 Ignition Off
Disconnect the LDP Connector.
Note: Check connectors - Clean/repair as necessary.
Engine off, key on.
Using a voltmeter, probe the Fused Ignition Switch Output Circuit.
Is the voltage above 10.0 volts?All
Ye s®Go To 5
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Disconnect the Engine Vacuum Supply Hose at the LDP.
Install a Vacuum Gauge to Engine Vacuum Supply Hose at the LDP.
Start engine and read Vacuum Gauge.
Does Vacuum Gauge read within 1 inch of engine vacuum?All
Ye s®Go To 6
No®Repair leak or obstruction in Vacuum Hose.
Perform Powertrain Verification Test VER-5A.
207
DRIVEABILITY
P-1494 LEAK DETECTION PUMP PRESSURE SWITCH ÐContinued
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TEST ACTION APPLICABILITY
6 Ignition Off
Disconnect the LDP Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the LDP Pressure Switch Sense
Circuit from the PCM Connector to a good ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the LDP Pressure Switch Sense Circuit for a short to
ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 7
7 Ignition Off
Disconnect the LDP Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the LDP Pressure Switch Sense
Circuit from the PCM Connector to the LDP Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair the open LDP Switch Sense Circuit.
Perform Powertrain Verification Test VER-5A.
8 Ignition Off
Disconnect the Engine Vacuum Supply Hose at the LDP.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Key on.
With voltmeter connected to LDP switch sense circuit at PCM connector, ground the
LDP solenoid control circuit. Then while applying vacuum to LDP with a hand
vacuum pump, observe voltmeter.
Did the voltage change?All
Ye s®Go To 9
No®Replace the LDP.
Perform Powertrain Verification Test VER-5A.
9 Ignition Off
If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-5A.
208
DRIVEABILITY
P-1494 LEAK DETECTION PUMP PRESSURE SWITCH ÐContinued
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Symptom:
P-1495 LEAK DETECTION PUMP SOLENOID CIRCUIT
When Monitored and Set Condition:
P-1495 LEAK DETECTION PUMP SOLENOID CIRCUIT
When Monitored: Immediately after a cold start, with ambient temperature between 4
deg C (40 deg F) and 32 deg C (90 deg F) and coolant temperature within ±12 deg C (10 deg
F) of ambient temperature.
Set Condition: The state of the solenoid does not change.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
LDP DEFECTIVE
LDP SOLENOID CKT WIRING HARNESS INTERMITTENT DEF
LDP SOLENOID CKT WIRING HARNESS OBSERVABLE DEFECT
LDP SOLENOID CONTROL CIRCUIT OPEN
LDP SOLENOID CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE
NO POSSIBLE CAUSES REMAINING
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, actuate the LDP Pump Solenoid.
Is it clicking?All
Ye s®Go To 2
No®Go To 5
2 Ignition On, Engine Not Running.
With the DRB, actuate the LDP Solenoid.
While monitoring the LDP Switch state, wiggle Wiring Harness from the LDP
Solenoid to PCM.
Did the LDP Switch state ever change from up to down when wiggled?All
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-6A.
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-6A.
No®Go To 4
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