CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
17 Ignition Off.
At the CKP Sensor, backprobe the CKP Sensor Signal Circuit with the Oscilloscope's
voltage measurement lead.
Start the Engine and observe the CKP Sensor voltage pattern on the Oscilloscope.
Are any Crankshaft Position Sensor Signals missing?ENGINE - 3.0L V6
Ye s®Go To 18
No®Go To 21
18 Ignition Off.
Disconnect the CKP Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 19
19 Ignition Off.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 20
20 Ignition Off.
Remove the Crankshaft Position (CKP) Sensor.
Inspect the Slots in the Flywheel for debris or damage.
Is the Flywheel damaged?ENGINE - 3.0L V6
Ye s®Repair or replace as necessary.
Perform Powertrain Verification Test VER-5A.
No®Replace the Crankshaft Position Sensor.
Perform Powertrain Verification Test VER-5A.
21 Start Engine.
At PCM, backprobe CKP Sensor Signal Circuit with Oscilloscope's voltage measure-
ment lead.
While observing the Oscilloscope pattern, wiggle CKP Sensor Circuit from Sensor to
PCM.
Were any CKP Sensor Signals missing when the wiggle test was conducted?ENGINE - 3.0L V6
Ye s®Note where wiggling the wires caused a missing CKP Sensor
signal. Repair Camshaft and Crankshaft Wire Harness as neces-
sary.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
195
DRIVEABILITY
P-1391 INTERMITTENT LOSS OF CMP OR CKP ÐContinued
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TEST ACTION APPLICABILITY
22 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 - 2.0L
and 2.4L I-4
DOHC
Ye s®Go To 23
No®Go To 27
23 Ignition Off.
Disconnect the CMP Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 24
24 Ignition Off.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out, or miswired?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 25
25 Ignition Off.
Disconnect the CMP Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Remove & inspect the CMP Sensor & Target Magnet for damage or misalignment.
Is the Camshaft Target Magnet okay?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Go To 26
No®Repair or replace Camshaft Target Magnet as necessary.
Perform Powertrain Verification Test VER-5A.
26 Ignition Off.
Disconnect the CMP Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Remove and inspect the CMP Sensor and Target Magnet for damage or mis-
alignment.
Check Camshaft endplay per pertinent service information.
Is the Camshaft endplay within specs?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Replace the Camshaft Position Sensor.
Perform Powertrain Verification Test VER-5A.
No®Repair or replace Camshaft/Cylinder Head as necessary.
Perform Verification Test VER-5A.
196
DRIVEABILITY
P-1391 INTERMITTENT LOSS OF CMP OR CKP ÐContinued
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TEST ACTION APPLICABILITY
27 Start Engine.
At PCM, backprobe CMP Sensor Signal Circuit with Oscilloscope's voltage measure-
ment lead.
While observing the Oscilloscope pattern, wiggle CMP Sensor Circuit from Sensor to
PCM.
Were any signals missing when the wiggle test was conducted?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Note where wiggling the Wires caused a missing CMP Sensor
Signal. Repair Camshaft and Crankshaft Wiring Harness as
necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 28
28 Ignition Off.
At the CKP Sensor, backprobe the CKP Sensor Signal Circuit with the Oscilloscope's
voltage measurement lead.
Start the Engine and observe the CKP Sensor voltage pattern on the Oscilloscope.
Are any Crankshaft Position Sensor Signals missing?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Go To 29
No®Test Complete.
29 Ignition Off.
Disconnect the CKP Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 30
30 Ignition Off.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair Terminal(s) for damage, pushout or miswiring.
Perform Powertrain Verification Test VER-5A.
No®Go To 31
31 Ignition Off.
Remove the Crankshaft Position (CKP) Sensor.
Inspect the Crankshaft notches for debris or damage.
Are the Crankshaft notches damaged?ENGINE - 2.0L
and 2.4L I-4
DOHC
Ye s®Repair or replace the Crankshaft as necessary.
Perform Powertrain Verification Test VER-5A.
No®Replace the Crankshaft Position Sensor.
Perform Powertrain Verification Test VER-5A.
197
DRIVEABILITY
P-1391 INTERMITTENT LOSS OF CMP OR CKP ÐContinued
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Symptom:
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored and Set Condition:
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored: Under closed throttle decel; A/C off; engine coolant temp > 23 degrees
C (75 degrees F); longer than 50 seconds after engine start. The speed at which the
deceleration occurs must be sufficient for the given gear range, e.g., > 36 Km/h (36 mph)
in first gear or > 104 Km/h (> 65) in high gear.
Set Condition: When one of the CKP Sensor target windows 15 degrees C (60 degrees F)
has more than 2.86% variance from the reference window.
POSSIBLE CAUSES
CKP SENSOR CONNECTOR OBSERVABLE DEFECT
CKP SENSOR CONNECTOR OBSERVABLE DEFECT
CKP SENSOR DEFECTIVE
CKP SENSOR DEFECTIVE
CKP SENSOR NOT PROPERLY INSTALLED
CKP SENSOR NOT PROPERLY INSTALLED
NOTCHES IN CRANKSHAFT DEFECTIVE
SLOTS IN FLEXPLATE DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?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-2A.
No®Go To 2
2 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Crankshaft Position Sensor for proper Torque and installation.
Is the Crankshaft Position Sensor properly installed?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 3
No®Properly install CKP Sensor.
Perform Verification Test VER-2A.
198
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off.
Remove the CKP Sensor.
Inspect the Slots in the Flexplate for debris, damage or excessive movement.
Is there any debris, damage or excessive movement?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 Powertrain Verification Test VER-2A.
No®Go To 4
4 If there are no potential causes remaining, the CKP Sensor is assumed to be
defective.
View repair options.ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Repair
Replace the CKP Sensor.
Perform Verification Test VER-2A.
5 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Repair as necessary.
Perform Verification Test VER-2A.
No®Go To 6
6 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Crankshaft Position Sensor for proper Torque and installation.
Is the Crankshaft Position Sensor properly installed?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Go To 7
No®Properly install CKP Sensor.
Perform Verification Test VER-2A.
7 Ignition Off.
Remove the Crankshaft Position Sensor.
Inspect the notches in the Crankshaft for debris, damage or excessive movement.
Is there any debris, damage or excessive movement?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
8 If there are no potential causes remaining, the CKP Sensor is assumed to be
defective.
View repair options.ENGINE -2.0L and
2.4L I-4 DOHC
Repair
Replace the CKP Sensor.
Perform Verification Test VER-2A.
199
DRIVEABILITY
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT ÐContinued
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Symptom:
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored and Set Condition:
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored: Amb temp bet 4 deg C (40deg F) & 32 deg C (90deg F), & coolant w/in
±12 deg C (10deg F) of amb. If PCM suspects pinch, no fault until runs evap purge flow
mon. Purge flow monitored w/eng temp >76 deg C (170deg F), engine in closed loop, idle 2
min, no low fuel, MAP <15.7 in. merc, & baro alt <8000 ft.
Set Condition: LDP must pass stricter evap system test first. No air flow through the
evaporative system is detected by the evap monitor.
POSSIBLE CAUSES
FUEL TANK TO EVAP CANISTER HOSE PINCHED
LDP PRESSURE HOSE BLOCKAGE
PURGE SOLENOID TO EVAP CANISTER HOSE PINCHED
LEAK DETECTION PUMP BLOCKAGE
EVAPORATIVE CANISTER BLOCKAGE LDP SIDE
EVAPORATIVE CANISTER BLOCKAGE SOLENOID SIDE
EVAP LEAK MONITOR PINCHED HOSE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1NOTE: Replacing the Powertrain Control Module will not correct this
problem.
With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the Evap Leak Monitor Pinched Hose Found does not exist or is an
intermittent problem.
With the DRB, read the FREEZE FRAME.
With this screen, 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 Evap Leak Monitor Pinched Hose Found reoccur?All
Ye s®Go To 3
No®Evap Leak Monitor Pinched Hose Found no longer exists.
Perform VERIFICATION TEST VER-6A.
200
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Remove Vacuum Connector from Purge Solenoid.
Did the pressure drop when the Vacuum Connector was removed?All
Ye s®Go To 4
No®Go To 6
4 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Disconnect Leak Detection Pump Pressure Hose from LDP.
Did pressure drop when hose was disconnected?All
Ye s®Replace the Leak Detection Pump.
Perform VERIFICATION TEST VER-6A.
No®Go To 5
5 Inspect the LDP Pressure Hose.
Is the hose OK?All
Ye s®Replace the Evaporative Canister.
Perform VERIFICATION TEST VER-6A.
No®Replace the LDP Pressure Hose.
Perform VERIFICATION TEST VER-6A.
201
DRIVEABILITY
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND ÐContinued
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TEST ACTION APPLICABILITY
6 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
If disconnected, reconnect the Vacuum Connector at the Purge Solenoid.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Remove hose at Evap Canister that goes to Purge Solenoid.
Did pressure drop when hose was disconnected?All
Ye s®Repair the pinched hose from the Purge Solenoid to the Evap
Canister.
Perform VERIFICATION TEST VER-6A.
No®Go To 7
7 To perform this test you will need Miller Tool Kit #6872A and #6922.
Caution: Refer to safety information.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Connect the Evap Pressure Pump Supply to Gas Cap Adapter and install on vehicle.
Start Engine.
With the DRB, go to LDP SYSTEM TEST and follow instructions on the screen.
Using Pressure Tool #6872A, set Pressure Hold to Open, and set Vent to Closed.
Turn Pump Timer On.
Allow Pressure Pump to build pressure up to at least 149H2O.
Remove hose at Evap Canister that goes to Fuel Tank.
Did pressure drop when hose was disconnected?All
Ye s®Replace the Evaporative Canister.
Perform VERIFICATION TEST VER-6A.
No®Repair the pinched hose from the Gas Tank to the Evap Canister.
Perform VERIFICATION TEST VER-6A.
202
DRIVEABILITY
P-1486 EVAP LEAK MONITOR PINCHED HOSE FOUND ÐContinued
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Symptom:
P-1491 RADIATOR FAN CONTROL RELAY CIRCUIT
When Monitored and Set Condition:
P-1491 RADIATOR FAN CONTROL RELAY CIRCUIT
When Monitored: With the ignition key on, battery voltage greater than 10 volts, and the
PCM requests the fans to be turned on.
Set Condition: An open or shorted condition is detected in the radiator fan relay control
circuit.
POSSIBLE CAUSES
FUSED B (+) CIRCUIT OPEN
RAD FAN RELAY OUTPUT CIRCUIT, 0 VOLTS TO BATTERY V
RADIATOR FAN RELAY GROUND CIRCUIT OPEN
RADIATOR FAN RELAY DEFECTIVE
RAD FAN RELAY CONTROL CIRCUIT SHORT TO GROUND
RADIATOR FAN MOTORS W/H INTERMITTENT DEFECT
RADIATOR FAN MOTORS W/H OBSERVABLE DEFECT
RADIATOR FAN RELAY CONTROL CIRCUIT OPEN
PCM DEFECTIVE (RADIATOR FAN MOTORS)
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, actuate the Radiator Fan Relay.
Are both of the Radiator Fan Motors cycling on and off?All
Ye s®Go To 2
No®Go To 4
2 Ignition On
With the DRB, actuate the Radiator Fan Relay.
Wiggle the Wiring Harness from the Relay to the PCM.
Did the wiggling interrupt the Radiator Fan Motor cycling?All
Ye s®Repair as necessary where wiggling caused the cycling to be
interrupted.
Perform Powertrain Verification Test VER-5A.
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-5A.
No®Test Complete.
203
DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition On
With the DRB, actuate the Radiator Fan Relay.
Using a voltmeter, the Fan Relay Output Circuit voltage at the Relay Connector.
Does the voltage cycle from below 1.0 volt to Battery voltage?All
Ye s®Repair or replace Radiator Fans or Relay to Fan Wiring as
necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 Ignition Off
Disconnect the Radiator Fan Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Turn key on.
Using a Voltmeter, measure the Fused B(+) Circuit at Relay Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 6
No®Repair the open Fused B (+) Circuit (check Radiator Fan Fuse in
PDC).
Perform Powertrain Verification Test VER-5A.
6 Ignition Off
Disconnect the Radiator Fan Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Radiator Fan Relay Ground Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the open Fan Relay Ground Circuit.
Perform Powertrain Verification Test VER-5A.
7 Ignition Off
Disconnect the Radiator Fan Relay Connector.
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Radiator Fan Relay Control Circuit to a good
ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Radiator Fan Relay Control Circuit for a short to
ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
8 Ignition Off
Disconnect the Radiator Fan Relay Connector.
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the Radiator Fan Relay Control
Circuit from the Relay to the PCM.
Is the resistance below 5.0 ohms?All
Ye s®Go To 9
No®Repair the open Radiator Fan Relay Control Circuit.
Perform Powertrain Verification Test VER-5A.
204
DRIVEABILITY
P-1491 RADIATOR FAN CONTROL RELAY CIRCUIT ÐContinued
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