oil CHRYSLER VOYAGER 2000 Diagnostic Manual

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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DRIVEABILITY
P-0305 CYLINDER #5 MIS-FIRE ÐContinued
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TEST ACTION APPLICABILITY
12 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.
Follow the equipment manufacturer's procedure for pattern analysis.
Is the secondary ignition pattern OK?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 13
No®Repair the indicated component in the Secondary Ignition Sys-
tem.
Perform VERIFICATION TEST VER-5A2.
13 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 ENGINE RPM over 3000 and the operating temp
normal?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®Lab scope cam and crank sensor, check valve timing, running
vacuum test.
Perform VERIFICATION TEST VER-5A2.
No®Go To 14
14The following additional items should be checked as possible mechanical
problems:
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions
ENGINE PCV SYSTEM - must flow freely
ENGINE DRIVE SPROCKETS - must be properly positioned
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?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-5A2.
No®Go To 15
15 The following are other possible causes for mis-fire:
Injector harness connectors, ignition coil circuit, spark plug, mechanical engine
problem, PCM power grounds, irregular cam and crank signal, injectors, restricted
exhaust, intake restriction, PCM, Evap System, EGR System, damaged trigger
wheel, and
accessory drive belts.
Do any of the above causes exist?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-5A2.
No®Test Complete.
107
DRIVEABILITY
P-0305 CYLINDER #5 MIS-FIRE ÐContinued
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Symptom:
P-0351 IGNITION COIL #1 PRIMARY CIRCUIT
When Monitored and Set Condition:
P-0351 IGNITION COIL #1 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, and none of the coils in dwell when checked.
Set Condition: Peak current is not achieved with 2.5ms of dwell. It takes 3 seconds during
cranking or up to 6 seconds while running to set.
POSSIBLE CAUSES
ASD OUTPUT CIRCUIT OPEN
IGNITION COIL #1 CONNECTOR TERMINAL OBSERVABLE DEF
IGNITION COIL #1 DRIVER CIRCUIT OPEN
IGNITION COIL #1 DRIVER CIRCUIT SHORTED TO GROUND
IGNITION COIL CIRCUIT WIRING HARNESS INTER DEFECT
IGNITION COIL CIRCUIT WIRING HARNESS OBS DEFECT
IGNITION COIL #1 RESISTANCE ABOVE 2.0 OHMS
PCM DEFECTIVE (IGN COIL #1)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?All
Ye s®Go To 2
No®Go To 8
2 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
With the DRB, actuate Ignition Coil #1.
With a Voltmeter, measure the ASD Output Circuit.
Is the voltage above 10.0 volts?All
No®Repair the open ASD Output Circuit.
Perform Powertrain Verification Test VER-5A.
Ye s®Go To 3
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Is any terminal damaged, pushed out or miswired?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 4
4 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the Ignition Coil #1 Primary Circuit for resistance.
Is the resistance below 2.0 ohms?All
Ye s®Go To 5
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Ignition Coil #1 Driver Circuit for resistance to
ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Ignition Coil #1 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, test the resistance of #1 Driver Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the open Ignition Coil #1 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
7 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.
8 Ignition Off
Start Engine.
Wiggle Wiring Harness from the Ignition Coil to the PCM.
Does the engine miss or stall?All
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 9
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DRIVEABILITY
P-0351 IGNITION COIL #1 PRIMARY CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
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®Test Complete.
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DRIVEABILITY
P-0351 IGNITION COIL #1 PRIMARY CIRCUIT ÐContinued
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Symptom:
P-0352 IGNITION COIL #2 PRIMARY CIRCUIT
When Monitored and Set Condition:
P-0352 IGNITION COIL #2 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, and none of the coils in dwell when checked.
Set Condition: Peak current is not achieved with 2.5ms of dwell. It takes 3 seconds during
cranking or up to 6 seconds while running to set.
POSSIBLE CAUSES
AUTO SHUTDOWN OUTPUT CIRCUIT OPEN
IGNITION COIL #2 CONNECTOR TERMINAL OBSERVABLE DEF
IGNITION COIL #2 DRIVER CIRCUIT OPEN
IGNITION COIL #2 DRIVER CIRCUIT SHORTED TO GROUND
IGNITION COIL CIRCUIT WIRING HARNESS INTER DEFECT
IGNITION COIL CIRCUIT WIRING HARNESS OBS DEFECT
IGNITION COIL #2 DEFECTIVE
PCM DEFECTIVE (IGN COIL #2)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?All
Ye s®Go To 2
No®Go To 8
2 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
With the DRB, actuate Ignition Coil #2.
With a Voltmeter, measure the ASD Output Circuit.
Is the voltage above 10.0 volts?All
Ye s®Go To 3
No®Repair the open ASD Output Circuit.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Is any Terminal damaged, pushed out or miswired?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Ignition Coil #2 Primary Circuit for resistance.
Is the resistance below 2.0 ohms?All
Ye s®Go To 5
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the resistance of the Ignition Coil Driver #2 Circuit to
ground at the PCM Connector.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Ignition Coil #2 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 Ignition Off
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, test the Ignition Coil #2 Driver Circuit for resistance.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the open Ignition Coil #2 Driver Circuit.
Perform Powertrain Verification Test VER-2A.
7 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-2A.
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DRIVEABILITY
P-0352 IGNITION COIL #2 PRIMARY CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Start Engine.
Wiggle Wiring Harness from the Ignition Coil to the PCM.
Does the engine miss or stall?All
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-2A.
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-2A.
No®Test Complete.
127
DRIVEABILITY
P-0352 IGNITION COIL #2 PRIMARY CIRCUIT ÐContinued
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Symptom:
P-0353 IGNITION COIL #3 PRIMARY CIRCUIT
When Monitored and Set Condition:
P-0353 IGNITION COIL #3 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, and none of the coils in dwell when checked.
Set Condition: Peak current is not achieved with 2.5ms of dwell. It takes 3 seconds during
cranking or up to 6 seconds while running to set.
POSSIBLE CAUSES
ASD OUTPUT CIRCUIT OPEN
IGNITION COIL CONNECTOR #3 TERMINAL OBSERVABLE DEF
IGNITION COIL #3 DRIVER CIRCUIT OPEN
IGNITION COIL #3 DRIVER CIRCUIT SHORTED TO GROUND
IGNITION COIL CIRCUIT WIRING HARNESS INTER DEFECT
IGNITION COIL CIRCUIT WIRING HARNESS OBS DEFECT
IGNITION COIL #3 RESISTANCE NOT ABOVE 2.0 OHMS
PCM DEFECTIVE (IGN COIL #3)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 2
No®Go To 8
2 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Key on.
With the DRB, actuate Ignition Coil #3.
With a Voltmeter, probe the ASD Output Circuit.
Is the voltage above 10.0 volts?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 3
No®Repair the open ASD Output Circuit.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Is any terminal damaged, pushed out, or miswired?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the Ignition Coil #3 Primary Circuit for resistance.
Is the resistance below 2.0 ohms?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 5
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of Ignition Coil #3 Driver Circuit to ground.
Is the resistance below 5.0 ohms?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Repair the Ignition Coil #3 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 Ignition Off
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the Ignition Coil #3 Driver Circuit for resistance from
the PCM Connector to the Coil Connector.
Is the resistance below 5.0 ohms?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 7
No®Repair the open Ignition Coil #3 Driver Circuit.
Perform Powertrain Verification Test VER-2A.
7 Ignition Off
If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
P-0353 IGNITION COIL #3 PRIMARY CIRCUIT ÐContinued
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