fuel pump CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
8 Turn ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Remove the pressure test port cap at the fuel rail test port. Connect a fuel pressure
gauge to the test port pressure fitting on the fuel rail.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/þ 5 psi.
Choose a conclusion that best matches your fuel pressure reading.All
Below Specification
Go To 9
Within Specification
Go To 13
Above Specification
Replace the fuel filter/pressure regulator.
Caution: Stop ALL Actuations.
9 Check for any of the following conditions/mechanical problems.
ENGINE VACUUM Ð must be at least 13 inches in neutral
ENGINE VALVE TIMING Ð must be within specifications
ENGINE COMPRESSION Ð must be within specifications
ENGINE EXHAUST SYSTEM Ð must be free of any restrictions or leaks.
ENGINE PVC SYSTEM Ð must flow freely
TORQUE CONVERTER STALL SPEED Ð must be within specifications
POWER BRAKE BOOSTER Ð no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR Ð plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?All
Ye s®Repair as necessary.
Perform FUEL SYSTEM/MISFIRE MONITOR VERIFICATION
TEST
No®Go To 10
10 Turn ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/169fuel line adapter tool #6539 between disconnected fuel line and
the fuel pump module.
Attach a fuel pressure test gauge to the ªT'' fitting on tool #6539.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/- 5 psi.
Is the fuel pressure within specification now?All
Ye s®Repair the restriction in the chassis fuel supply line between the
fuel tank and fuel rail.
No®Go to 11
Caution: Stop ALL Actuations.
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P0172 -1/1 FUEL SYSTEM RICH ÐContinued
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TEST ACTION APPLICABILITY
11Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?All
Ye s®Replace the Fuel Inlet Strainer.
No®Go To 12
12 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.All
Repair
Replace the Fuel Pump Module
13 Check for any of the following conditions/mechanical problems.
ENGINE VACUUM Ð must be at least 13 inches in neutral
ENGINE VALVE TIMING Ð must be within specifications
ENGINE COMPRESSION Ð must be within specifications
ENGINE EXHAUST SYSTEM Ð must be free of any restrictions or leaks.
ENGINE PVC SYSTEM Ð must flow freely
TORQUE CONVERTER STALL SPEED Ð must be within specifications
POWER BRAKE BOOSTER Ð no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR Ð plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?All
Ye s®Repair as necessary.
Perform FUEL SYSTEM/MISFIRE MONITOR VERIFICATION
TEST
No®Test Complete.
14 The conditions required to set the DTC are no longer present.
With the DRB read and record the freeze frame data and the ªFuel System Similar
Conditions Window'' data.
Utilize the data and try to duplicate the operating conditions at which the DTC was
set. Pay particular attention to the ECT and RPM for added diagnostics.
Note: Refer to any TSB's that may apply to the symptom.
Test Complete
Repair
Test Complete.
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P0172 -1/1 FUEL SYSTEM RICH ÐContinued
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POSSIBLE CAUSES
OTHER POSSIBLE CAUSES FOR MIS-FIRE
CAM, CRANK, VALVE TIMING, OR VACUUM PROBLEM
ELECTRONIC IGNITION COIL OUTPUT LOW
ENGINE MECHANICAL PROBLEM
SECONDARY IGNITION PATTERN IRREGULAR
FUEL CONTAMINATION
FUEL PRESSURE LEAK DOWN OUT OF SPECIFICATION
FUEL PUMP AMPERAGE OUT OF SPECIFICATION
FUEL PUMP CAPACITY OUT OF SPECIFICATION
FUEL PUMP PRESSURE OUT OF SPECIFICATION
MIS-FIRE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the MIS-FIRE GOOD TRIP counter displayed and equal to zero?All
Ye s®Go To 2
No®Go To 3
2 At this time the conditions that set this fault are present.
With the DRB, read the FREEZE FRAME and SIMILAR CONDITIONS WINDOWS.
Attempt to operate the vehicle in the similar conditions.
When the vehicle is operating in the SIMILAR CONDITIONS WINDOW, go to the
WHICH CYLINDER IS MISFIRING screen.
Is the DRB counting mis-fires at this time?All
Ye s®Go To 4
No®Go To 3
3 At this time the mis-fire does not exist or is an intermittent problem.
With the DRB, read the FREEZE FRAME and SIMILAR CONDITIONS WINDOW.
With these screens, 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 mis-fire reoccur?All
Ye s®Go To 4
No®Mis-fire no longer exists.
Perform VERIFICATION TEST VER-5A2.
4 With the DRB, read the FREEZE FRAME DATA.
Use the freeze frame data and attempt to determine the cause.
In the FREEZE FRAME, are the adaptive fuel percentages greater than +/- 15%?All
Ye s®Go To 5
No®Go To 10
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P-0300 MULTIPLE CYLINDER MIS-FIRE ÐContinued
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TEST ACTION APPLICABILITY
5 With an appropriate container, obtain a fuel sample from the vehicle.
Is the fuel free from contamination?All
Ye s®Go To 6
No®Replace contaminated fuel and clean system.
Perform VERIFICATION TEST VER-5A2.
6 Perform Fuel Pressure Leak Down Test per service instructions.
Did the Fuel Pressure Leak Down Test pass?All
Ye s®Go To 7
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
7 Perform Fuel Pump Amperage Test per service instructions.
Did the Fuel Pump Amperage Test pass?All
Ye s®Go To 8
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
8 Perform Fuel Pump Capacity Test per service instructions.
Did the Fuel Pump Capacity Test pass?All
Ye s®Go To 9
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
9 Perform Fuel Pump Pressure Test per service instructions.
Did the Fuel Pump Pressure Test pass?All
Ye s®Go To 10
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
10 With the DRB, read the FREEZE FRAME DATA.
Use the freeze frame data and attempt to determine the cause.
In the FREEZE FRAME, is the LOAD VALUE over 50% and the temp normal
operating temp normal?All
Ye s®Go To 12
No®Go To 11
11 With the DRB, read the FREEZE FRAME window.
Use the freeze frame data and attempt to determine the cause.
In the FREEZE FRAME, is the ENGINE RPM over 3000 and the operating temp
normal?All
Ye s®Lab scope cam and crank sensor, check valve timing, running
vacuum test.
Perform VERIFICATION TEST VER-5A2.
No®Go To 14
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P-0300 MULTIPLE CYLINDER MIS-FIRE ÐContinued
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Symptom List:
P-0305 CYLINDER #5 MIS-FIRE
P-0306 CYLINDER #6 MIS-FIRE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P-0305 CYLINDER #5 MIS-FIRE.
When Monitored and Set Condition:
P-0305 CYLINDER #5 MIS-FIRE
When Monitored: With the engine running, after successfully performing Crank Sensor
learn.
Set Condition: When more than a 2% misfire rate is measured during two trips, or with
a 10% to 30% misfire rate during one trip.
P-0306 CYLINDER #6 MIS-FIRE
When Monitored: With the engine running, after successfully performing Crank Sensor
learn.
Set Condition: When more than a 2% misfire rate is measured during two trips, or with
a 10% to 30% misfire rate during one trip.
POSSIBLE CAUSES
OTHER POSSIBLE CAUSES FOR MIS-FIRE
CAM, CRANK, VALVE TIMING, OR VACUUM PROBLEM
ELECTRONIC IGNITION COIL OUTPUT LOW
ENGINE MECHANICAL PROBLEM
SECONDARY IGNITION PATTERN IRREGULAR
FUEL CONTAMINATION
FUEL PRESSURE LEAK DOWN OUT OF SPECIFICATION
FUEL PUMP AMPERAGE OUT OF SPECIFICATION
FUEL PUMP CAPACITY OUT OF SPECIFICATION
FUEL PUMP PRESSURE OUT OF SPECIFICATION
MIS-FIRE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the MIS-FIRE GOOD TRIP counter displayed and equal to zero?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 2
No®Go To 3
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TEST ACTION APPLICABILITY
7 Perform Fuel Pump Amperage Test per service instructions.
Did the Fuel Pump Amperage Test pass?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 8
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
8 Perform Fuel Pump Capacity Test per service instructions.
Did the Fuel Pump Capacity Test pass?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 9
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
9 Perform Fuel Pump Pressure Test per service instructions.
Did the Fuel Pump Pressure Test pass?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 10
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
10 With the DRB, read the FREEZE FRAME DATA.
Use the freeze frame data and attempt to determine the cause of the misfire.
In the FREEZE FRAME, is the LOAD VALUE over 50% and the temp normal
operating temp?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 11
No®Go To 13
11 Engine Off.
Connect a suitable engine analyzer to the engine.
Allow the Engine to idle.
NOTE: If the Engine will not idle, maintain a constant RPM above idle.
NOTE: Set the scope to read display or parade pattern.
Remove any spark plug wire.
Observe the Secondary KV Line.
Is the open secondary voltage at least 25 KV?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 12
No®Replace the Electonic Ignition Coil.
Perform VERIFICATION TEST VER-5A2.
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P-0305 CYLINDER #5 MIS-FIRE ÐContinued
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TEST ACTION APPLICABILITY
3Note: Leaving the Gas Cap loose could cause this trouble code to set.
To continue testing you will need Miller Tool Kit #6872A and #8382.
NOTE: The Fuel Tank must have 1/2 tank of fuel to perform this test.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Warning: Verify the vehicle fuel tank contains at least 3 gallons of fuel.
Attach the DRB III to the vehicle.
Turn the Key On.
At: ENGINE SYSTEM TESTS select: LEAK DETECTION PUMP TEST.
Read instructions and then press ENTER.
At: LEAK DETECTION PUMP TEST select #3 HOLD PSI.
At the vacuum hose going to the LDP, attach and apply a continuous vacuum (i.e. 209
Hg).
Remove Gas Cap.
Install 8382 on the Gas Cap and on the vehicle.
Attach the supply hose from 6872A to 8382.
Attach the power source from the 6872A, clip to Battery(+) and ground clip to
Battery(-).
On the 6872A set the Pressure/Hold Valve to Open and set the Vent Valve to Closed.
Turn the timer on and watch the gauge.
When the gauge pressure reaches 14 in. H2O, turn the Pressure/Hold Valve to
Closed.
Turn the timer off. Note the time and pressure.
Did pressure drop more than 6 in. H2O (to 8 inches H2O on the gauge) in two
minutes?All
Ye s®Go To 4
No®Go To 5
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P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED ÐContinued
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TEST ACTION APPLICABILITY
4 To continue testing you will need Miller Tool Kit #6872A, #8382 and #6904 Ultrasonic
Leak Detector.
NOTE: The Fuel Tank must have 1/2 tank of fuel to perform this test.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Warning: Verify the vehicle fuel tank contains at least 3 gallons of fuel.
Attach the DRB III to the vehicle.
Turn the Key On.
At: ENGINE SYSTEM TESTS select: LEAK DETECTION PUMP TEST.
Read instructions and then press ENTER.
At: LEAK DETECTION PUMP TEST select #3 HOLD PSI.
At the vacuum hose going to the LDP, attach and apply a continuous vacuum (i.e. 209
Hg).
Remove Gas Cap.
Install 8382 on the Gas Cap and on the vehicle.
Attach the supply hose from 6872A to 8382.
Attach the power source from the 6872A, clip to Battery(+) and ground clip to
Battery(-).
Set Pressure Hold to Open and set Vent to Open.
Turn Pump Timer On.
To prevent noise from interfering with test, move tool #6872 away from vehicle.
Using the Ultrasonic Leak Detector, start listening for leaks at Gas Cap then proceed
to Rollover Valve, Canister, Leak Detection Pump, and Evap Purge Solenoid.
Were any leaks heard with the Ultrasonic Leak Detector?All
Ye s®Repair or replace leaking component.
Perform VERIFICATION TEST VER-6A.
No®Replace Leak Detection Pump.
Perform VERIFICATION TEST VER-6A.
5 At this time, the condition required to set the code is not present.
Using the schematic as a guide, inspect the wiring, connectors and hoses.
Were any problems found?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-6A.
No®Test Complete.
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P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED ÐContinued
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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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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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