engine CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
15 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Ignition On , Engine Not Running.
With a Voltmeter, measure the Fuel Pump Relay Fused B(+) Circuit.
Is the voltage above 10.0 volts?ENGINE - 3.0L V6
Ye s®Go To 16
No®Repair the open Fuel Pump Relay Fused B(+) Circuit.
Perform Powertrain Verification Test VER-1A.
16 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note; Check Connectors - clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
Ignition On, Engine Not Running.
Actuate the ASD Fuel System test.
With a Voltmeter, measure the Fuel Pump Relay Output Circuit.
Is the voltage above 10.0 volts?ENGINE - 3.0L V6
Ye s®Go To 17
No®Repair the open Fuel Pump Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
17 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Install a substitute Relay of the same part number for the Fuel Pump Relay.
Attempt to start the Engine.
Does the engine start?ENGINE - 3.0L V6
Ye s®Replace the Fuel Pump Relay.
Perform Powertrain Verification Test VER-1A.
No®Go To 18
18 Ignition off.
If there are no potential causes remaining, the Fuel Pump is assumed to be defective.
View repair options.ENGINE - 3.0L V6
Repair
Replace the Fuel Pump.
Perform Powertrain Verification Test VER-1A.
19Note: Ensure the SKIM has proper communication and that there are no
SKIM DTC's present before continuing.
Ignition Off.
Ensure the Throttle Cables are not holding the Throttle open.
Is the Throttle held open?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Repair condition that holds the Throttle Body open.
No®Go To 20
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* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
20 Ignition On, Engine Not Running
With the DRB, actuate the Fuel System and check for Fuel Pump operation at the
Fuel Tank.
Is the Fuel Pump operating?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 21
No®Go To 30
21 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Install a Fuel Pressure Gauge to the Fuel Rail.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
For 3.3 liter engines fuel pressure should be 50 to 60 psi, and for all other engines fuel
pressure should be 43 to 53 psi.
Is the Fuel pressure above the specification ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 22
No®Go To 25
22 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 23
23 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 24
No®Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-1A.
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* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
24 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Return Tube for restriction between fuel Filter and Fuel Pump Module.
Is there a restriction ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace restricted Fuel Tube.
Perform Powertrain Verification Test VER-1A.
No®Test Complete.
25 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Tee-In a Fuel Pressure Gauge into the Fuel Hose using tool #6433.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 PSI for Gasoline, 50 to 60 PSI for (E85) Ethanol.
Is the Fuel pressure below the specification ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 26
No®Test Complete.
26 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove adapter 6631 and reinstall Fuel Line.
Install adapter 6631 between Fuel Pump and Fuel Filter.
Connect Fuel Pressure Gauge to adapter 6631.
Key On.
With the DRB, actuate Fuel System.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 27
27 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pump Module.
Inspect the Fuel Pump Inlet Strainer.
Is the Inlet Strainer plugged?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Inlet Strainer.
Perform Powertrain Verification Test VER-1A.
No®Go To 28
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* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
28 Record the Fuel Pressure Gauge reading.
Ignition Key Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pressure Gauge.
Install adapter 6631 between Fuel Filter Outlet and Chassis Fuel Supply Tube.
Connect Fuel Pressure Gauge to adapter 6631.
Ignition On, Engine Not Running.
With DRB, actuate the ASD Fuel System.
Record the Fuel Pressure Gauge reading.
Compare this reading with the previous reading.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Repair restriction in Chassis Fuel Supply Line between Fuel
Filter and Fuel Rail.
Perform Powertrain Verification Test VER-1A.
No®Go To 29
29 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Repair
Replace Fuel Pump Module.
Perform Powertrain Verification Test VER-1A.
30 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note: Check connectors - Clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
With an Ohmmeter, measure the Fuel Pump Ground Circuit.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 31
No®Repair the open Fuel Pump Ground Circuit.
Perform Powertrain Verification Test VER-1A.
31 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Ignition On , Engine Not Running.
With a Voltmeter, measure the Fuel Pump Relay Fused B(+) Circuit.
Is the voltage above 10.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 32
No®Repair the open Fuel Pump Relay Fused B(+) Circuit.
Perform Powertrain Verification Test VER-1A.
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* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
32 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note; Check connectors - Clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
Ignition On, Engine Not Running.
Actuate the ASD Fuel System test.
With a Voltmeter, measure the Fuel Pump Relay Output Circuit.
Is the voltage above 10.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 33
No®Repair the open Fuel Pump Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
33 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Install a substitute Relay of the same part number for the Fuel Pump Relay.
Attempt to start the Engine.
Does the Engine start?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Pump Relay.
Perform Powertrain Verification Test VER-1A.
No®Go To 34
34 Ignition Off.
If there are no potential causes remaining, the Fuel Pump is assumed to be defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Repair
Replace the Fuel Pump.
Perform Powertrain Verification Test VER-1A.
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* CHECKING THE FUEL SYSTEM ÐContinued
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Symptom:
* CHECKING THE IDLE AIR CONTROL MOTOR
POSSIBLE CAUSES
ENGINE NOT START AND STAY RUNNING
IAC MOTOR DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Hold the Engine Throttle 1/4 of the way down. Attempt to start the Engine.
Does the Engine start and stay running?All
Ye s®Go To 2
No®Refer to Symptom list for further diagnostic tests.
2 Ignition Off
Remove the IAC Motor.
Turn key on.
With the DRB in Actuator Tests, actuate the IAC Stepper Motor.
Observe the Pintle of the IAC Motor.
Is the IAC Motor Pintle moving in and out?All
Ye s®Test Complete.
No®Note: Ensure there are no IAC Motor related Trouble Codes
Before Making the following repair. Replace the IAC motor.
Perform Powertrain Verification Test VER-1A.
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Symptom:
* CHECKING THE SECONDARY IGNITION SYSTEM
POSSIBLE CAUSES
GOOD SPARK AT SPARK PLUG #1
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
COIL SECONDARY CABLE DEFECTIVE
FUSED B(+) CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
IGNITION COIL CONNECTOR OBSERVABLE DEFECT
IGNITION COIL CONNECTOR OBSERVABLE DEFECT
IGNITION COIL DEFECTIVE
IGNITION COIL SECONDARY CABLE #1 DEFECTIVE
IGNITION COIL SECONDARY CABLE #4 DEFECTIVE
SECONDARY IGNITION COMPONENT(S) DEFECTIVE
SPARK PLUG CABLE #1 DEFECTIVE
AUTO SHUTDOWN RELAY DEFECTIVE
AUTO SHUTDOWN RELAY DEFECTIVE
IGNITION COIL DEFECTIVE
IGNITION COIL DEFECTIVE (RESISTANCE OUT OF RANGE)
SPARK PLUG #1 OR #4 DEFECTIVE
GOOD SPARK AT SPARK PLUG #1
GOOD SPARK AT SPARK PLUG #1
TEST ACTION APPLICABILITY
1 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #1.
Connect the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Warning: Ensure that there are no Fuel or Fuel vapors present in or near
the Engine compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 3.0L V6
Ye s®Refer to Symptom list for further diagnostic tests.
No®Go To 2
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TEST ACTION APPLICABILITY
2 Ignition Off.
Remove the Coil Secondary Cable from the Distributor.
Hold the Cable within 1/49of a good Ground.
Caution: Engine Controller damage may occur if more than 1/4(.
While cranking the Engine for 10 seconds, watch for spark.
Note: Consider 1 or 2 sparks as a No Spark condition.
Is there good spark?ENGINE - 3.0L V6
Ye s®Repair the Secondary Ignition: Distributor Cap, Rotor, Cables.
Perform Verification TEST VER-1A
No®Go To 3
3 Ignition Off
Remove the Coil Secondary Cable.
With an Ohmmeter, test the Coil Secondary Cable for resistance.
Is the resistance above 15 Kohms?ENGINE - 3.0L V6
Ye s®Replace the Coil Secondary Cable.
Perform Verification TEST VER-1A
No®Go To 4
4 Ignition Off.
Remove the Distributor Cap.
While cranking the Engine, watch for the Rotor to turn.
Did the Rotor turn when the Engine was cranked?ENGINE - 3.0L V6
Ye s®Go To 5
No®Go To 14
5 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Key On
With the DRB, actuate Ignition Coil.
With a Voltmeter, measure the ASD Output Circuit.
Is the voltage above 10 volts?ENGINE - 3.0L V6
Ye s®Go To 6
No®Go To 11
6 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Using an Ohmmeter, measure each Ignition Coil Primary Circuit for resistance.
Is the resistance below 2.0 ohms for each measurement?ENGINE - 3.0L V6
Ye s®Go To 7
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-1A.
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
7 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-1A.
No®Go To 8
8 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, test the resistance of the Ignition Coil Driver Circuit.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 9
No®Repair the open Ignition Coil Driver Circuit.
Perform Powertrain Verification Test VER-1A.
9 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Ignition Coil Driver Circuit at the PCM Conn. to
Ground.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Repair the Ignition Coil Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-1A.
No®Go To 10
10 Ignition off.
If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ENGINE - 3.0L V6
Repair
Replace the Powertrain Control Module.
Perform Powetrain Verification Test VER-1A.
11 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
12 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Jumper Wire connect the ASD Relay Output Circuit to Ground at the
Ignition Coil Connector.
With an Ohmmeter mesaure the ASD Output Circuit for resistance to Ground at the
Relay.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 13
No®Repair open ASD Relay Output Circuit.
Perform Powetrain Verification Test VER-1A.
13 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Ignition On, Engine Not Running.
With a Voltmeter, measure the Fused B(+) Circuit cavity B in ASD Relay Connector.
Is the voltage above 10 volts?ENGINE - 3.0L V6
Ye s®Replace the Auto Shutdown Relay.
Perform Powertrain Verification Test VER-1A.
No®Repair open Fused B+.
Perform Verification TEST VER-1A
14 Ignition Off.
Remove the Distributor Cap.
Is the Distributor Rotor loose?ENGINE - 3.0L V6
Ye s®Repair loose Distributor Rotor as necessary.
Perform Verification TEST VER-1A
No®Go To 15
15 If there are no potential causes remaining, the Distributor Drive System is assumed
to be defective.
View repair options.ENGINE - 3.0L V6
Repair
Repair the Distributor Drive System.
Perform Powertrain Verification Test VER-1A.
16 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #1.
Connect the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Warning: Ensure that there are no Fuel or Fuel vapors present in or near
the Engine compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Refer to Symptom list for further diagnostic tests.
No®Go To 17
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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