engine CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
5 Ignition on, engine not running.
With the DRB, perform the SRI Memory Test.
Does the DRB display9Write Failure?9All
Ye s®Replace the Powertrain Control Module.
Perform Verification Test VER-2A.
No®Go To 6
6 Ignition on, engine not running.
Compare SRI mileage stored value to the Instrument Panel Odometer mileage.
Is the mileage the same?All
Ye s®Retest the SRI Memory.
Perform Powertrain Verification Test VER-2A.
No®Go To 7
7 Ignition off.
If there are no potential causes remaining, the SRI Memory is assumed to be in need
of updating.
View repair options.All
Repair
Update the mileage and retest the SRI Memory.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
P-1696 PCM FAILURE EEPROM WRITE DENIED ÐContinued
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Symptom:
P-1698 NO CCD MESSAGES FROM TCM
When Monitored and Set Condition:
P-1698 NO CCD MESSAGES FROM TCM
When Monitored: With the engine running.
Set Condition: No CCD messages are received from the TCM for 10 seconds.
POSSIBLE CAUSES
DRB DOES NOT SHOW BUS OPERATIONAL
CCD WIRING HARNESS OBSERVABLE DEFECT
CCD BUS (+) CIRCUIT OPEN BETWEEN PCM AND TCM
CCD BUS (-) CIRCUIT OPEN BETWEEN PCM AND TCM
PCM DEFECTIVE (NO CCD MESSAGE)
TCM DEFECTIVE (NO CCD MESSAGE)
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, select9Transmission9.
Note: The CCD Bus test is automatic.
Does the DRB show9Bus Operational9?All
Ye s®Go To 2
No®Go to the appropriate symptom group for body diagnostics.
2 Ignition Off
With the DRB, select9Engine9module.
With the DRB erase trouble codes.
Raise all four wheels off the ground and properly support the vehicle.
Caution: Keep clear of rotating wheels in the next step.
Start the engine. Place the Shift Lever in Drive and allow the wheels to rotate for 1
minute.
Step on the brakes, put the Shift Lever back in Park.
With the DRB read Trouble Codes.
Does display show9No CCD Message from TCM9and the start run counter equal to
zero?All
Ye s®Go To 3
No®Go To 7
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DRIVEABILITY
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Symptom:
CHECKING 5 VOLT SUPPLY CIRCUIT
POSSIBLE CAUSES
5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
5-VOLT SUPPLY WIRING HARNESS INTER DEF
A/C PRESSURE SENSOR DEFECTIVE
MAP SENSOR DEFECTIVE
THROTTLE POSITION SENSOR DEFECTIVE
PCM DEF (5 VOLT SUPPLY CIRCUIT)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
Disconnect the Throttle Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary
With a voltmeter, probe the 5-Volt Supply Ckt at the TP Sensor harness connector.
Is the voltage reading below 4.5 volts?All
Ye s®Go To 2
No®Go To 6
2 Ignition On, Engine Not Running.
Disconnect the Throttle Position Sensor Connector.
Disconnect the A/C Pressure Sensor.
Note: Check connectors - Clean/repair as necessary.
With a voltmeter, probe the TP Sensor 5-Volt Supply Circuit to the TP Sensor.
Is the 5-Volt Supply Circuit voltage above 4.0 volts?All
Ye s®Replace the A/C Pressure Sensor.
Perform Powertrain Verificaton Test VER-2A.
No®Go To 3
3 Ignition On, Engine Not Running
Disconnect the Throttle Position Sensor Connector.
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
With the voltmeter, probe the TP Sensor 5-Volt Supply Circuit to the TP Sensor.
Is the 5-Volt Supply Circuit voltage above 4.0 volts?All
Ye s®Replace the Map Sensor.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Disconnect the Throttle Position Sensor Connector.
Disconnect the MAP Sensor Electrical Connector.
Disconnect the A/C Sensor Connector.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
With the ohmmeter, probe the 5-volt supply circuit at the TPS Connector.
Is the resistance below 5.0 ohms?All
Ye s®Repair the 5-volt Supply Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 5
5 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 On, Engine Not Running
Disconnect the MAP Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
With the voltmeter, probe the 5-Volt Supply Ckt at the MAP Sensor Connector.
Is the voltage reading below 4.5 volts?All
Ye s®Replace the TPS.
Perform Powertrain Verification Test VER-2A.
No®Test Complete.
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DRIVEABILITY
CHECKING 5 VOLT SUPPLY CIRCUIT ÐContinued
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Symptom:
* CHECKING EGR SYSTEM
POSSIBLE CAUSES
VACUUM LINE TO EGR SOLENOID RESTRICTION OR LEAK
VACUUM NIPPLE AT THROTTLE BODY PLUGGED
EGR VALVE ASSEMBLY DEFECTIVE
EGR VALVE ASSEMBLY DOES NOT HOLD VACUUM
EGR VALVE ASSEMBLY TONE CHANGED
EGR VALVE ASSEMBLY VACUUM <= 3 INCHES
PASSAGES BETWEEN EGR VALVE AND INTAKE CLOSED
TEST ACTION APPLICABILITY
1 Ignition Off
Disconnect the Vacuum Supply Hose at the EGR Solenoid.
Connect a vacuum gauge to the disconnected Vacuum Supply Hose.
Start the Engine.
Was the vacuum above 109at idle?All
Ye s®Go To 2
No®Go To 10
2 Ignition Off
Connect Back Pressure Hose to transducer.
Connect a hand pump to the EGR Valve Nipple.
Start the Engine.
Slowly apply vacuum to the EGR Valve, watch for Engine speed to drop.
Did the Engine speed drop?All
Ye s®Go To 3
No®Go To 6
3 Ignition Off
Adjust a shop air source to 20 PSI and connect to Backpressure Tube at base of EGR
Valve.
While opening and closing the throttle, listen for a tone change.
Did the tone change?All
Ye s®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Connect a hand pump to the EGR Valve Nipple.
Apply 10 inches of vacuum and hold for 30 seconds.
Did the Vacuum hold for 30 seconds?All
Ye s®Go To 5
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
5 Engine Running
Disconnect the EGR Valve Hose from the EGR Valve.
Connect the vacuum gauge to the disconnected EGR Valve Hose.
While watching the gauge, unplug EGR Solenoid Electrical Connector.
Is the Vacuum over 3 inches at this time?All
Ye s®Test Complete.
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
6 Ignition Off
Adjust a shop air source to 20 PSI and connect to Backpressure Tube at base of EGR
Valve.
While opening and closing the throttle, listen for a tone change.
Did the tone change?All
Ye s®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
No®Go To 7
7 Engine Running
Disconnect the EGR Valve Hose from the EGR Valve.
Connect the vacuum gauge to the disconnected EGR Valve Hose.
While watching the gauge, unplug EGR Solenoid Electrical Connector.
Is the Vacuum over 3 inches at this time?All
Ye s®Go To 8
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
8 Ignition Off
Remove the EGR Valve Assembly and inspect passages from Valve to Intake
Manifold.
Were passages open between EGR Valve and intake?All
Ye s®Go To 9
No®Repair the EGR Passages as necessary.
Perform Verification Test VER-2A.
9 Ignition Off
If there are no potential causes remaining, the EGR Valve Assembly is assumed to be
defective.
View repair options.All
Repair
Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
10 Ignition Off
Disconnect the EGR Vacuum Supply Hose at the Intake Manifold.
Connect a vacuum gauge to the Intake Manifold Nipple.
Read the vacuum gauge at idle.
Was the vacuum above 109at idle?All
Ye s®Repair the restriction or leak in the vacuum line to EGR Solenoid.
Perform Verification Test VER-2A.
No®Go To 11
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DRIVEABILITY
* CHECKING EGR SYSTEM ÐContinued
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Symptom:
* CHECKING ENGINE VACUUM
TEST ACTION APPLICABILITY
1 Ignition Off
Connect a Vacuum Gauge to a Vacuum Source on the Engine.
Start the Engine and allow it to idle.
Note: The normal vacuum reading will vary according to the altitude.
While monitoring the vacuum gauge, snap the throttle open a few times. Refer to
vacuum gauge specifications in support material.
Observe the Vacuum Gauge reading at idle.
Is the Vacuum Gauge reading between 13 inches and 22 inches steady?All
Ye s®Test Complete.
No®Refer to symptom * CHECKING THE ENGINE MECHANICAL
SYSTEMS in the DRIVEABILITY category.
231
DRIVEABILITY
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Symptom:
* CHECKING EVAPORATIVE EMISSION SYSTEM
POSSIBLE CAUSES
EVAP PURGE SOLENOID DEFECTIVE
EVAP PURGE SOLENOID DEFECTIVE
EVAPORATIVE CANISTER DEFECTIVE
EVAPORATIVE EMISSION VACUUM HOSE OBSERVABLE DEFECT
VACUUM LINE OBSERVABLE DEFECT
VACUUM LINE PLUGGED
VACUUM LINE PLUGGED
TEST PASSED
TEST ACTION APPLICABILITY
1 Ignition Off
Note: Carefully inspect all Vacuum Hoses for proper routing and for
pinched or plugged Hoses from the engine to the PPS to the Gas Tank.
Are all the Vacuum Hoses OK?All
Ye s®Go To 2
No®Repair the Vacuum Hoses as necessary.
Perform Powertrain Verification Test VER-2A.
2 Ignition Off
Start the engine and allow it to reach normal operating temperature 76 deg C (170
deg. F).
Turn ignition off.
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Start the engine.
Note: There should be no flow through the Solenoid from 1 to 2 minutes.
Is the PPS allowing vacuum through the Solenoid within 1 minute?All
Ye s®Go To 3
No®Go To 6
3 Ignition Off
Inspect the line from the PPS to the Canister.
Is the line disconnected, ripped or cut?All
Ye s®Repair the Line and replace the Purge Solenoid.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Remove the Purge Solenoid and tap the ports against a clean solid surface.
Did any foreign material fall out?All
Ye s®Go To 5
No®Replace the Evap Purge Solenoid.
Perform Powertrain Verification Test VER-6A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
5 If there are no potential causes remaining, the Vacuum Line is assumed to be
defective.
View repair options.All
Repair
Clean out the Line and replace the PPS and Canister.
Perform Powertrain Verification Test VER-2A.
6 Ignition Off
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Note: In the next steps, do not use more that five PSI.
Attempt to blow air through the Vacuum Line that goes to the canister.
Does the Canister and Vacuum Line allow air to pass?All
Ye s®Purge Solenoid and hoses OK. Test passed.
No®Go To 7
7 Ignition Off
Start the engine and allow it to reach normal operating temperature 76 deg C (170
deg F).
Turn ignition off.
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Start the engine.
Note: After 90 seconds, the Purge Solenoid will allow vacuum to cycle
intermittently at a steady rate.
Is the Evap Solenoid allowing vacuum to cycle through intermittently at a steady
rate?All
Ye s®Go To 8
No®Replace the Purge Solenoid.
Perform Powertrain Verification Test VER-6A.
8 Ignition Off
Note: In the next steps, do not use more than five psi.
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Disconnect the Vacuum Line at the Canister that goes to the EVAP Solenoid.
Attempt to blow air through the Vacuum Line that goes to the Canister.
Does the Vacuum Line allow air to pass?All
Ye s®Go To 9
No®Repair or replace the Vacuum Line.
Perform Powertrain Verification Test VER-2A.
9 If there are no potential causes remaining, the Evaporative Canister is assumed to be
defective.
View repair options.All
Repair
Replace the Evaporative Canister.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
* CHECKING EVAPORATIVE EMISSION SYSTEM ÐContinued
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Symptom:
* CHECKING FOR OXYGEN SENSOR SWITCHING
POSSIBLE CAUSES
O2 SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
ENGINE VACUUM ABNORMAL
FUEL DELIVERY SYSTEM DEFECTIVE
O2 SENSOR DEFECTIVE
AIR INLET SYSTEM RESTRICTED
TEST ACTION APPLICABILITY
1 Engine Running
Note: the Engine must be running and at normal operating temperature.
Note: The Downstream O2 Sensor should switch slower than the Upstream
O2 Sensor.
With the DRB, read the O2 Sensor voltages for 10 seconds or more.
Are the O2 Sensor voltages switching normally?All
Ye s®Test Complete.
No®Go To 2
2 Engine Running
Note: The Engine must be running and at normal operating temperature.
Note: The Downstream O2 Sensor should switch slower than the Upstream
O2 Sensor.
With the DRB, read the O2 Sensor voltages for 10 seconds or more.
Is the Upstream O2 Sensor locked9LEAN9?All
Ye s®Go To 3
No®Go To 9
3 Ignition On, Engine Not Running
With the DRB, read the O2 Sensor Signal voltages.
Is the voltage below 0.10 volts for the Upstream or Downstream O2 Sensor?All
Ye s®Go To 4
No®Go To 7
4 Engine Running
Allow the Engine to idle.
Inspect the Engine for any abnormal vacuum conditions.
Are there any abnormal vacuum conditions?All
Ye s®Repair abnormal Engine Vacuum condition as required.
Perform Powertrain Verification Test VER-2A.
No®Go To 5
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DRIVEABILITY
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