ignition CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
3 Ignition off.
Remove the Throttle Body per service information procedure.
Note: Clean Throttle Body in a well ventilated area and wear rubber gloves.
While holding the Throttle open spray entire Throttle Body Bore with Mopar parts
cleaner.
Using a soft scuff pad, clean the Throttle Body Bore and Throttle Plate.
Using compressed air, dry the Throttle Body and install Throttle Body on Manifold.
Reconnect IAC Motor Connector and reset the IAC Motor Steps with the DRB.
Start engine and let idle.
With the DRB, actuate the minimum air flow.
Is the idle RPM within the range shown in the chart? Refer to the Service
Information.All
Ye s®Test Complete.
No®Replace the Throttle Body.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Start engine, allow engine idle to stabilize for 60 seconds.
With the DRB, read target idle and engine RPM.
Is the engine RPM within +200/-100 RPM of target idle?All
Ye s®Go To 5
No®Go To 8
5 Ignition Off
Remove the IAC Motor from the housing.
Turn Ignition on with Engine Not Running.
With the DRB, actuate the IAC Stepper Motor.
Wiggle the Wiring Harness from the IAC Motor to the PCM.
Did the IAC stop operating at any time?All
Ye s®Repair the Harness or Connectors as necessary.
Perform Powertrain Verification Test VER-5A.
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-5A.
No®Go To 7
7 Ignition On, Engine Not Running
Check Throttle Plate and Linkage for a binding condition.
The Throttle Linkage must be free and the Throttle Plate at the idle
position.
Ensure Throttle Plate is fully closed and against its stop.
Is the Throttle Plate and Linkage okay?All
Ye s®Test Complete.
No®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
P-1294 TARGET IDLE NOT REACHED ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Start engine, allow engine idle to stabilize for 60 seconds.
With the engine running at idle, the DRB in Systems Test, perform the IAC wiggle
test.
The idle speed should raise and lower with the display.
Does the RPM raise and lower correctly?All
Ye s®Go To 9
No®Refer to symptom P-0505 IDLE AIR CONTROL MOTOR CIR-
CUITS in the DRIVEABILITY category.
9 Ignition Off
Start engine, allow engine idle to stabilize for 60 seconds.
Check engine Vacuum Hoses and Components for vacuum leaks.
Ensure PCV Valve is the correct part and is operating correctly.
Were any problems found?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 10
10 Ignition Off
Remove the IAC Motor from the housing.
Turn Ignition on with Engine Not Running.
With the DRB, actuate the IAC Stepper Motor.
Wiggle the Wiring Harness from the IAC Motor to the PCM.
Did the IAC stop operating at any time?All
Ye s®Repair the Harness or Connectors as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 11
11 Ignition On, Engine Not Running
Check Throttle Plate and Linkage for a binding condition.
The Throttle Linkage must be free and the Throttle Plate at the idle
position.
Ensure Throttle Plate is fully closed and against its stop.
Is the Throttle Plate and Linkage okay?All
Ye s®Go To 12
No®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
12 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.
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DRIVEABILITY
P-1294 TARGET IDLE NOT REACHED ÐContinued
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Symptom:
P-1297 NO CHANGE IN MAP FROM START TO RUN
When Monitored and Set Condition:
P-1297 NO CHANGE IN MAP FROM START TO RUN
When Monitored: Engine is idling with a stable RPM (RPM fluctuation < 64 RPM) and
the vehicle is not moving.
Set Condition: Too small a difference is seen between barometric pressure at ignition on
and manifold vacuum.
POSSIBLE CAUSES
MAP SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
MAP SENSOR WIRING HARNESS INTERMITTENT DEF
VACUUM PORTS RESTRICTED OR DEFECTIVE
MANIFOLD ABSOLUTE PRESSURE SENSOR RESTRICTED
MAP SENSOR DEFECTIVE (A)
MAP SENSOR DEFECTIVE (B)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes
Is9MAP Sensor voltage too low9code set?All
Ye s®Refer to symptom P-0107 MAP SENSOR VOLTAGE TOO LOW in
the DRIVEABILITY category.
No®Go To 2
2 With the DRB erase Codes.
Ignition On, Engine Not Running
Start engine and allow engine to idle for 30 seconds.
With the DRB read codes.
Does the DRB show9No change in MAP from start to run9?All
Ye s®Go To 3
No®Go To 6
3 Ignition on, with engine not running.
Disconnect MAP Sensor.
Note:Check connectors - clean/repair as necessary.
Ignition on, with engine not running.
Using a Voltmeter, measure the MAP Sensor 5-Volt Supply Circuit at the MAP
Sensor Connector.
Is the voltage above 4.0 volts?All
Ye s®Go To 4
No®Repair the open MAP Sensor 5-volt Supply Circuit.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition off.
Remove MAP Sensor and inspect for Vacuum restrictions.
Check connectors - Clean/repair as necessary.
Was there a restriction?All
Ye s®Remove the restriction and reinstall the MAP Sensor
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 If there are no potential causes remaining, the MAP Sensor is assumed to be
defective.
View repair options.All
Repair
Replace the MAP Sensor.
Perform Powertrain Verification Test VER-5A.
6 Engine must be running.
While monitoring the DRB display, snap the Throttle open and closed.
Did the vacuum drop rapidly below 1.09?All
Ye s®Go To 7
No®Go To 8
7 Engine must be running.
With the DRB,set the engine speed to 1500 RPM.
With the engine RPM at 1500, read MAP sensor voltage.
While monitoring the voltage, wiggle the wiring from the MAP Sensor to PCM.
Did the engine stall or voltage become erratic?All
Ye s®Repair the Wiring or Connector defective between the Map
Sensor and the PCM.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
8 Engine must be running.
With the DRB,set the engine speed to 1500 RPM.
With the engine RPM at 1500, read MAP sensor voltage.
While monitoring the voltage, wiggle the wiring from the MAP Sensor to PCM.
Did the engine stall or voltage become erratic?All
Ye s®Repair the Wiring or Connector defective between the Map
Sensor and the PCM.
Perform Powertrain Verification Test VER-5A.
No®Go To 9
9 Ignition Off
Remove the MAP Sensor and inspect condition of Intake Manifold and MAP Sensor
Vacuum Ports.
Check connectors - Clean/repair as necessary.
Is there a restriction or defect in the Vacuum Ports?All
Ye s®Repair the restricted or defective Vacuum Ports.
Perform Powertrain Verification Test VER-5A.
No®Go To 10
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DRIVEABILITY
P-1297 NO CHANGE IN MAP FROM START TO RUN ÐContinued
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Symptom:
P-1388 AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P-1388 AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Monitored: With ignition key on and battery voltage greater than 10 volts.
Set Condition:
POSSIBLE CAUSES
FUSED B(+) CIRCUIT OPEN
AUTO SHUTDOWN RELAY RESISTANCE>=100.0 OHMS
ASD RELAY CONTROL CIRCUIT WIRING HARNESS INTER DEF
ASD RELAY CONTROL CIRCUIT WIRING HARNESS OBSER DEF
AUTO SHUTDOWN RELAY CONTROL CIRCUIT OPEN
AUTO SHUTDOWN RELAY CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE (AUTO SHUTDOWN RELAY CONTROL CIRCUIT)
TEST ACTION APPLICABILITY
1 Ignition on, Engine Not Running
The ASD Relay is referred to as the Low Pressure Shutoff Relay in CNG
applications.
With the DRB, actuate the Auto Shutdown Relay.
Is the ASD Relay clicking?All
Ye s®Go To 2
No®Go To 4
2 Engine running.
Wiggle the Wiring Harness from the ASD Relay to the PCM.
Did the engine die out when wiggling wires?All
Ye s®Repair circuit as necessary where wiggling caused the engine to
die out.
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.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Remove the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure the B(+) Circuit at ASD Relay Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 5
No®Repair the open Fused B(+) Circuit.
Perform Powertrain Verification Test VER-2A.
5 Ignition off.
Remove the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Use an ohmmeter in the following step.
Measure the resistance across Terminals A (86) and C (85) of the ASD Relay.
Is the resistance between 50.0 and 90.0 ohms?All
Ye s®Go To 6
No®Replace the ASD Relay.
Perform Powertrain Verification Test VER-2A.
6 Ignition Off
Remove the ASD Relay.
Check Connectors - clean/repair as necessary.
Disconnect the PCM Connector.
Check Connectors - clean/repair as necessary.
Use an ohmmeter in the following step.
Using an ohmmeter, measure the resistance of the ASD Relay Control Circuit from
the ASD Relay to the PCM Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the open ASD Relay Control Circuit.
Perform Powertrain Verification Test VER-2A.
7 Ignition off.
Remove the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the ASD Relay Control Ckt to ground..
Is the resistance below 5.0 ohms?All
Ye s®Repair the ASD Relay Control Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
8 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-2A.
187
DRIVEABILITY
P-1388 AUTO SHUTDOWN RELAY CONTROL CIRCUIT ÐContinued
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Symptom:
P-1389 NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Monitored and Set Condition:
P-1389 NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Monitored: With ignition key on and battery voltage greater than 10 volts.
Set Condition: Engine running and no ASD Relay Output Sense at PCM.
POSSIBLE CAUSES
FUSED B(+) CIRCUIT OPEN
ASD RELAY DEFECTIVE
ASD RELAY OUT CKT WIRING HARNESS OBSERVABLE DEFECT
ASD RELAY OUTPUT CIRCUIT OPEN (ENGINE STARTED)
ASD RELAY OUTPUT CKT OPEN (ENGINE DID NOT START)
ASD RLY OUT CKT WIRING HARNESS INTERMITTENT DEFECT
PCM DEFECTIVE (ENGINE DID NOT START)
PCM DEFECTIVE (ENGINE STARTED)
TEST ACTION APPLICABILITY
1 Ignition off.
Is a Trouble Code also set for9ASD Relay Control Circuit?All
Ye s®Refer to symptom P-1388 AUTO SHUTDOWN RELAY CON-
TROL CIRCUIT in the DRIVEABILITY category.
No®Go To 2
2 Ignition on with engine not running.
With the DRB, read Trouble Codes.
Attempt to start the engine and let idle.
Is the Global Good Trip displayed and equal to 0?All
Ye s®Go To 3
No®Go To 10
3 Ignition off.
Attempt to start the engine.
Did the engine start?All
Ye s®Go To 4
No®Go To 6
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Remove the Auto Shutdown Relay.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the resistance of the ASD Relay Output Circuit from
ASD Relay to the PCM Connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-2A.
No®Go To 5
5 Ignition off.
If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-2A.
6 Ignition Off
Remove the Auto Shutdown Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure the Fused B (+) Circuit at Relay Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 7
No®Repair the open Fused B(+) Circuit. (Check Engine Fuse in PDC)
.
Perform Powertrain Verification Test VER-2A.
7 Ignition Off
Remove the Auto Shutdown Relay.
Note: Check connectors - Clean/repair as necessary.
Install a substitute Relay for the Auto Shutdown Relay.
Attempt to start the Vehicle.
Did the engine start?All
Ye s®Replace the original Auto Shutdown Relay.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
8 Ignition Off.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Remove the Auto Shutdown Relay.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the resistance of the ASD Relay Output Circuit from
the Auto Shutdown Relay to the PCM.
Is the resistance above 5.0 ohms?All
Ye s®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-2A.
No®Go To 9
189
DRIVEABILITY
P-1389 NO ASD RELAY OUTPUT VOLTAGE AT PCM ÐContinued
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TEST ACTION APPLICABILITY
9 Ignition off.
If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-2A.
10 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®Go To 11
11 Start Engine.
Note: The Engine must be running before continuing test.
Wiggle Wiring Harness from ASD Relay to the Powertrain Control Module.
With the DRB, read Trouble Codes.
Did trouble code9No ASD Relay Output Voltage at PCM9reset?All
Ye s®Repair as necessary where wiggling caused the Trouble Code to be
set.
Perform Powertrain Verification Test VER-2A.
No®Test Complete.
190
DRIVEABILITY
P-1389 NO ASD RELAY OUTPUT VOLTAGE AT PCM ÐContinued
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Symptom:
P-1391 INTERMITTENT LOSS OF CMP OR CKP
When Monitored and Set Condition:
P-1391 INTERMITTENT LOSS OF CMP OR CKP
When Monitored: Engine running over 7 seconds.
Set Condition: When the expected cam signal level disagrees with the actual cam signal
level.
POSSIBLE CAUSES
CKP SENSOR CKT WIRING HARNESS INTER DEF
CMP SENSOR SIGNAL CKT WIRING HARNESS INTER DEF
CAMSHAFT POSITION SENSOR DEFECTIVE
CAMSHAFT SPROCKET DEFECTIVE
CRANKSHAFT DEFECTIVE
CRANKSHAFT POSITION SENSOR DEFECTIVE
DISTRIBUTOR PULSE RING DEFECTIVE
FLYWHEEL DEFECTIVE
CAMSHAFT TARGET MAGNET DEFECTIVE
CAMSHAFT THRUST PLATES(S) NOT ATTACHED
CKP SENSOR CONNECTOR TERMINALS OBS DEF
CKP SENSOR CONNECTOR TERMINALS OBS DEFECT
PCM CONN TERMINALS OBS DEF (CKP SENSOR)
PCM CONN TERMINALS OBS DEF (CMP SENSOR)
CAMSHAFT/CYLINDER HEAD DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off.
At the CMP Sensor, backprobe the CMP Sensor Signal Circuit with the Oscilloscope
voltage measurement lead.
Start the Engine and observe the CMP Sensor voltage pattern on the Oscilloscope.
Are there any of the Camshaft Position Sensor Signals missing?ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6 and/or EN-
GINE - 3.3L V6
FFV
Ye s®Go To 2
No®Go To 6
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DRIVEABILITY
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