engine CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
5 Ignition Off
Disconnect the Upstream or Downstream O2 Sensor Connector that the voltage is
below 0.10 volts.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance between the O2 Sensor Signal Circuit
and a good ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the O2 Sensor Signal Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 If there are no potential causes remaining, the Upstream or Downstream O2 Sensor
is assumed to be defective.
View repair options.All
Repair
Replace the Upstream or Downstream O2 Sensor that was below
0.10 volts.
Perform Powertrain Verification Test VER-2A.
7 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 8
8 Engine Running
With the DRB, reset the Adaptive Fuel Memory.
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®Refer to symptom * CHECKING THE ENGINE MECHANICAL
SYSTEMS in the DRIVEABILITY category.
9 Ignition Off
Install a Fuel Pressure Gauge to the Fuel Line. Use special tools if necessary.
Turn ignition on.
With the DRB, actuate the ASD Fuel System Test.
Allow Fuel Pressure to stabilize.
With the DRB, stop Fuel System Test. Monitor the Pressure Gauge for 1 minute.
Is the Fuel Pressure below 10 psi?All
Ye s®If Fuel Pump and Lines are OK, replace leaking Injector(s) as
necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 10
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DRIVEABILITY
* CHECKING FOR OXYGEN SENSOR SWITCHING ÐContinued
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TEST ACTION APPLICABILITY
10 Ignition Off
Inspect the Air Filter and Inlet Ducts for restriction(s).
Were there any restrictions?All
Ye s®Repair or replace the Air Inlet System as necessary.
Perform Powertrain Verification Test VER-2A.
No®Refer to symptom * CHECKING THE ENGINE MECHANICAL
SYSTEMS in the DRIVEABILITY category.
236
DRIVEABILITY
* CHECKING FOR OXYGEN SENSOR SWITCHING ÐContinued
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Symptom:
* CHECKING FUEL DELIVERY
POSSIBLE CAUSES
FUEL LINE RESTRICTED
FUEL FILTER DEFECTIVE
FUEL LINE RESTRICTED
FUEL PRESSURE REGULATOR DEFECTIVE
FUEL PUMP/REGULATOR ASSEMBLY DEFECTIVE
FUEL RETURN LINE DEFECTIVE
FUEL PUMP/REGULATOR ASSEMBLY DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel Pressure.
Connect a Fuel Pressure Gauge to test port.
Ignition On, Engine Not Running
With the DRB, actuate Fuel System. Fuel Pressure should be 43 to 53 psi.
Fuel Pressure should be 43 to 53 psi.
Is the Fuel Pressure within the specification?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Go To 2
No®Go To 5
2 Ignition Off
Note: Make sure the Gear Lever is in neutral, and the Park Brakes engaged.
Start the engine.
Monitor the Fuel Pressure Gauge in the next step.
While monitoring the pressure, momentarily snap Throttle wide open raising RPM to
above 3000.
Did the fuel pressure drop below 35 psi at all?All
Ye s®Go To 3
No®Test Complete.
3 Ignition Off
Inspect the Chassis Fuel Supply Line to the engine for a kink or restriction.
Is the line kinked or restricted?All
Ye s®Release the fuel pressure. Repair the Fuel Line as necessary.
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
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Adjust a shop air hose to 40 psi.
Remove the Fuel Filter.
Using shop air, inspect the Fuel Filter passage by attempting to blow air through
inlet.
Is the Fuel Filter restricted?All
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Replace the Fuel Pump and Regulator Assembly.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel Pressure.
Connect a Fuel Pressure Gauge to test port.
Ignition On, Engine Not Running.
With the DRB, actuate Fuel System. Fuel Pressure should be 43 to 53 psi for Gasoline
Engines and 50 to 60 psi for Flexible Fuel Vehicle.
Record the Fuel Pressure reading.
Is the Fuel Pressure above the specification?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Go To 6
No®Go To 8
6 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Remove the Fuel Return Line between the Fuel Tank and Filter.
Adjust a shop air hose to 40 psi.
Using shop air, inspect the Fuel Line by attempting to blow air through it.
Is the Fuel Return Line restricted?All
Ye s®Replace the Fuel Return Line.
Perform Powertrain Verification Test VER-2A.
No®Go To 7
7 If there are no potential causes remaining, the Fuel Pressure Regulator is assumed
to be defective.
View repair options.All
Repair
Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-2A.
238
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Inspect the Chassis Fuel Supply Line to engine for a kink or restriction.
Is the Line kinked or restricted?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 9
9 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is the Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Go To 10
10 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Test Complete.
No®Release the Fuel Pressure. Replace the Fuel Pump and Regulator
Assembly.
Perform Powertrain Verification Test VER-2A.
11 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Relieve the Fuel Pressure.
Tee-in Fuel Pressure Gauge into the Fuel Supply Hose using Tool #6433.
Turn ignition on.
With the DRB, actuate the ASD Fuel System test.
Is the Fuel Pressure between 43 and 53 psi?ENGINE - 3.0L V6
Ye s®Go To 12
No®Go To 15
12 Ignition Off
Note: Make sure the Gear Lever is in neutral, and the Park Brakes engaged.
Start the engine.
Monitor the Fuel Pressure Gauge in the next step.
While monitoring the pressure, momentarily snap Throttle wide open raising RPM to
above 3000.
Did the fuel pressure drop below 35 psi at all?All
Ye s®Go To 13
No®Test Complete.
239
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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TEST ACTION APPLICABILITY
13 Ignition Off
Inspect the Chassis Fuel Supply Line to the engine for a kink or restriction.
Is the line kinked or restricted?All
Ye s®Release the fuel pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 14
14 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Adjust a shop air hose to 40 psi.
Remove the Fuel Filter.
Using shop air, inspect the Fuel Filter passage by attempting to blow air through
inlet.
Is the Fuel Filter restricted?All
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Replace the Fuel Pump and Regulator Assembly.
Perform Powertrain Verification Test VER-2A.
15 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve the Fuel Pressure.
Tee-in Fuel Pressure Gauge into the Fuel Supply Hose using Tool #6433.
Turn Ignition On.
With the DRB, actuate the ASD Fuel System test.
Record the Fuel Pressure reading.
Is the Fuel Pressure above 53 psi?ENGINE - 3.0L V6
Ye s®Go To 16
No®Go To 18
16 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Remove the Fuel Return Line between the Fuel Tank and Filter.
Adjust a shop air hose to 40 psi.
Using shop air, inspect the Fuel Line by attempting to blow air through it.
Is the Fuel Return Line restricted?All
Ye s®Replace the Fuel Return Line.
Perform Powertrain Verification Test VER-2A.
No®Go To 17
17 If there are no potential causes remaining, the Fuel Pressure Regulator is assumed
to be defective.
View repair options.All
Repair
Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-2A.
240
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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TEST ACTION APPLICABILITY
18 Ignition Off
Inspect the Chassis Fuel Supply Line to engine for a kink or restriction.
Is the Fuel Line kinked or restricted?ENGINE - 3.0L V6
Ye s®Release the Fuel Pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 19
19 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Install Fuel Pressure Gauge between Fuel Tank and Fuel Filter.
Key on.
With the DRB, actuate the ASD Fuel System test.
Is fuel pressure at least 5 psi higher than the previously recorded pressure?ENGINE - 3.0L V6
Ye s®Release the Fuel Pressure. Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Go To 20
20 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Install Fuel Pressure Gauge between Fuel Tank and Fuel Filter.
Key on.
With the DRB, actuate the ASD Fuel System test.
Is fuel pressure at least 5 psi higher than the previously recorded pressure?ENGINE - 3.0L V6
Ye s®Test Complete.
No®Release the Fuel Pressure. Replace the Fuel Pump and Regulator
Assembly.
Perform Powertrain Verification Test VER-2A.
241
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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Symptom:
* CHECKING IDLE AIR CONTROL MOTOR
POSSIBLE CAUSES
ENGINE SPEED WITHIN TOLERANCE
IAC MOTOR CONNECTOR OBSERVABLE DEFECT
ENGINE HAS VACUUM LEAKS
IAC MOTOR DEFECTIVE
TEST ACTION APPLICABILITY
1 Engine Running
With the DRB in actuator tests, set the engine speed to 1400 RPM and then to 900
RPM.
Did the engine RPM go from 1400 RPM to 900 RPM?All
Ye s®With the DRB, stop all tests, test complete.
No®Go To 2
2 Engine Running
Inspect the engine for any vacuum leak(s).
Is there any vacuum leaks?All
Ye s®Repair Vacuum Leak(s) as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 3
3 Turn the ignition off.
Disconnect the IAC motor harness connector.
Start the engine and allow it to idle.
Using a test light connected to ground, probe the IAC Driver #1 circuit.
Repeat the above test for the remaining IAC Driver circuits.
Did the test light turn on and off at any time for each IAC driver circuit?All
Ye s®Go To 4
No®Go To 5
4 Turn the ignition off.
Disconnect the IAC motor harness connector.
Start the engine and allow it to idle.
Using a test light connected to battery positive, probe the IAC Driver #1 circuit.
Repeat the above test for the remaining IAC Driver circuits.
Did the test light turn on and off at any time for each IAC driver circuit?All
Ye s®Go To 6
No®Go To 8
242
DRIVEABILITY
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Symptom:
* CHECKING INTAKE AIR TEMPERATURE SENSOR
POSSIBLE CAUSES
INTAKE AIR TEMPERATURE SENSOR DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
Do not allow more than 5 minutes delay between next 2 steps.
With the DRB, read the Intake Air Temperature Sensor and record the reading.
Turn Ignition off.
Remove the IAT Sensor, then proceed to next step.
Using a Temperature Probe, quickly measure intake temperature inside IAT Sensor
opening.
Is the IAT Sensor within ±12 degrees C (10 degrees F) of the probe reading?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Test Complete.
No®Replace the Intake Air Temperature Sensor.
Perform Verification Test VER-2A.
244
DRIVEABILITY
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Symptom:
* CHECKING MAP SENSOR CALIBRATION
POSSIBLE CAUSES
MAP SENSOR DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Tee-in a Vacuum Gauge to a Manifold Vacuum source.
Start the engine.
Allow engine to idle.
Note: If engine will not idle, maintain a constant RPM above idle.
Using the DRB, read MAP Sensor Vacuum.
Is the reading within 1 inch of the teed-in Vacuum Gauge?All
Ye s®Go To 2
No®Replace the MAP Sensor.
Perform Verification Test VER-2A.
2 Ignition Off
Disconnect the MAP Sensor Harness Connector.
Ignition On.
Using a voltmeter, measure the 5±volt supply circuit.
Is the voltage above 4.0 volts?All
Ye s®Test Complete.
No®Repair the open 5±volt supply circuit.
Perform Verification Test VER-2A.
245
DRIVEABILITY
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