relay CHRYSLER VOYAGER 2000 Diagnostic Manual

Symptom:
P-0203 INJECTOR #3 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0203 INJECTOR #3 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
POSSIBLE CAUSES
ASD RELAY OUTPUT CIRCUIT OPEN
FUEL INJECTOR #3 DEFECTIVE
INJECTOR #3 DRIVER CIRCUIT OPEN
INJECTOR #3 DRIVER CIRCUIT SHORTED TO GROUND
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Start engine, let idle for at least 20 seconds.
Key on, engine off.
With the DRB, read Trouble Codes.
Is the Global Good Trip counter displayed and equal to zero?All
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Note: It may be necessary to remove the Intake Plenum in the following
steps.
Disconnect the Injector #3 Connector.
Note: Check connectors - Clear/repair as necessary.
Using an Ohmmeter, measure the resistance of Injector #3.
Is the resistance between 10.0 and 16.0 ohms?All
Ye s®Go To 3
No®Replace the Fuel Injector.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off.
Note: It may be necessary to remove the Intake Plenum in the following
steps.
Disconnect the Injector #3 Connector.
Note: Check connectors - Clean/repair as necessary.
Ignition On, Engine Not Running.
With the DRB, actuate the Auto Shutdown Relay.
Using a Voltmeter, measure the ASD Relay output voltage.
Does the voltage cycle high and low?All
Ye s®Go To 4
No®Repair the open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off.
Note: It may be necessary to remove the Intake Plenum in the following
steps.
Disconnect the Injector #3 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #3 Driver from the PCM to the Injector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open Injector #3 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off.
Note: It may be necessary to remove the Intake Plenum in the following
steps.
Disconnect the Injector #3 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #3 Driver Circuit to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Injector #3 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.All
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
7 Engine Running
Wiggle Wiring Harness from the Injector to the PCM.
Does the engine miss or stall?All
Ye s®Repair as necessary where wiggling caused the problem to
appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
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P-0203 INJECTOR #3 CONTROL CIRCUIT ÐContinued
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Symptom:
P-0204 INJECTOR #4 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0204 INJECTOR #4 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
POSSIBLE CAUSES
ASD RELAY OUTPUT CIRCUIT OPEN
INJECTOR #4 DEFECTIVE
INJECTOR #4 DRIVER CIRCUIT OPEN
INJECTOR #4 DRIVER CIRCUIT SHORTED TO GROUND
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Start engine, let idle for at least 20 seconds.
Key on, engine off.
With the DRB, read Trouble Codes.
Is the Global Good Trip counter displayed and equal to zero?ALL
Ye s®Go To 2
No®Go To 7
2Note: It may be necessary to remove the Intake Plenum in the following
steps.
Key off.
Disconnect the #4 Injector Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #4.
Is the resistance between 10.0 and 16.0 ohms?ALL
Ye s®Go To 3
No®Replace the Fuel Injector.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3Note: It may be necessary to remove the Intake Plenum in the following
steps.
Disconnect the #4 Injector Connector.
Note: Check connectors - Clean/repair as necessary.
Turn ignition on.
With the DRB, actuate the Auto Shutdown Relay.
Using a Voltmeter, measure the ASD Relay Output voltage.
Does the voltage cycle high and low?ALL
Ye s®Go To 4
No®Repair the open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-5A.
4Note: It may be necessary to remove the Intake Plenum in the following
steps.
Key off.
Disconnect the Injector #4 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure across the Injector #4 Driver Circuit from the PCM to
the Injector.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 5
No®Repair the open Injector #4 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5Note: It may be necessary to remove the Intake Plenum in the following
steps.
Key off.
Disconnect the #4 Injector Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #4 Driver Circuit to ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the Injector #4 Control Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ALL
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
7 Engine Running
Wiggle Wiring Harness from the Injector to the PCM.
Does the engine miss or stall?ALL
Ye s®Repair as necessary where wiggling caused the problem to
appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
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DRIVEABILITY
P-0204 INJECTOR #4 CONTROL CIRCUIT ÐContinued
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Symptom:
P-0205 INJECTOR #5 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0205 INJECTOR #5 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
POSSIBLE CAUSES
ASD RELAY OUTPUT CIRCUIT OPEN
INJECTOR #5 DEFECTIVE
INJECTOR #5 DRIVER CIRCUIT OPEN
INJECTOR #5 DRIVER CIRCUIT SHORT TO GROUND
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Start engine, let idle for at least 20 seconds.
Key on, engine off.
With the DRB, read Trouble Codes.
Is the Global Good Trip counter displayed and equal to zero?ENGINE - 3.0L,
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 7
2 Ignition Off
Disconnect Injector #5 Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #5.
Is the resistance between 10.0 and 16.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 3
No®Replace the Fuel Injector.
Perform Powertrain Verification Test VER-5A.
3 Ignition Off
Disconnect Injector #5 Connector.
Note: Check connectors - Clean/repair as necessary.
Turn the ignition on.
With the DRB, actuate the Auto Shutdown Relay.
Using a Voltmeter, measure the ASD Relay Output voltage.
Does the voltage cycle high and low?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 4
No®Repair the open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-5A.
95
DRIVEABILITY
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Symptom:
P-0206 INJECTOR #6 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0206 INJECTOR #6 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
POSSIBLE CAUSES
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
INJECTOR #6 DEFECTIVE (RESISTANCE OUT OF RANGE)
INJECTOR #6 DRIVER CIRCUIT OPEN
INJECTOR #6 DRIVER CIRCUIT SHORTED TO GROUND
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Start engine, let idle for at least 20 seconds.
Key on, engine off.
With the DRB, read Trouble Codes.
Is the Global Good Trip counter displayed and equal to zero?ENGINE - 3.0L,
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 7
2 Ignition Off
Note: It may be necessary to remove the Intake Plenum in the following
step.
Disconnect the Injector #6 Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #6.
Is the resistance between 10.0 and 16.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 3
No®Replace the Fuel Injector.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Note: It may be necessary to remove the Intake Plenum in the following
step.
Disconnect the Injector #6 Connector.
Note: Check connectors - Clean/repair as necessary.
Turn ignition on.
With the DRB, actuate the ASD Relay.
Using a Voltmeter, measure the ASD Relay Output voltage.
Does the voltage cycle high and low?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 4
No®Repair the open Auto Shutdown Relay Output Circuit.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Note: It may be necessary to remove the Intake Plenum in the following
step.
Disconnect the Injector #6 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #6 Driver Circuit from the PCM to the
Injector.
Is the resistance below 5.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 5
No®Repair the open Injector #6 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Note: It may be necessary to remove the Intake Plenum in the following
step.
Disconnect the Injector #6 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #6 Driver Circuit to ground.
Is the resistance below 5.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair the Injector #6 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 It there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
98
DRIVEABILITY
P-0206 INJECTOR #6 CONTROL CIRCUIT ÐContinued
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Symptom:
P-0645 A/C CLUTCH RELAY CIRCUIT
When Monitored and Set Condition:
P-0645 A/C CLUTCH RELAY CIRCUIT
When Monitored: With the ignition key on and battery voltage greater than 10 volts.
Set Condition: An open or shorted condition is detected in the A/C clutch relay control
circuit.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
AIR CONDITIONING CLUTCH RELAY DEFECTIVE
A/C CLUTCH RELAY CIRCUIT WITHOUT INTER DEFECT
A/C CLUTCH RELAY CIRCUIT WITHOUT OBSER DEFECT
A/C CLUTCH RELAY CONTROL CIRCUIT SHORT TO GROUND
AIR CONDITIONING CLUTCH RELAY CONTROL CIRCUIT OPEN
PCM DEF (A/C CLUTCH RELAY)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
Actuate the Air Conditioning Clutch Relay.
Is the Air Conditioning Clutch Relay clicking?All
Ye s®Go To 2
No®Go To 4
2 Ignition On, Engine Not Running
Actuate the Air Conditioning Clutch Relay.
Wiggle the Wiring Harness from the Relay to the PCM.
Did the wiggling interrupt the clicking?All
Ye s®Repair as necessary where wiggling caused the clicking to be
interrupted.
Perform Powertrain Verification Test VER-2A.
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-2A.
No®Test Complete.
170
DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Remove the Air Conditioning Clutch Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure the Fused Ignition Switch Output Circuit.
Is the voltage above 10.0 volts?All
Ye s®Go To 5
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off
Remove the Air Conditioning Clutch Relay.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the resistance between terminals C (85) and A (86) of
the Air Conditioning Clutch Relay.
Is the resistance below between 50 to 90 ohms?All
Ye s®Go To 6
No®Replace the Air Conditioning Clutch Relay.
Perform Powertrain Verification Test VER-2A.
6 Ignition Off
Disconnect the PCM grey connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the A/C Clutch Control Circuit from the PCM
connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Air Conditioning Clutch Relay Control Circuit for a
short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 7
7 Ignition Off
Disconnect the PCM grey connector.
Remove the Air Conditioning Clutch Relay.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the resistance of the Air Conditioning Clutch Relay
Control Circuit from the relay to the PCM.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair open Air Conditioning Clutch Relay Control Circuit.
Perform Powertrain Verification Test VER-2A.
8 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.
171
DRIVEABILITY
P-0645 A/C CLUTCH RELAY CIRCUIT ÐContinued
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Symptom:
P1282 FUEL PUMP RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P±1282 FUEL PUMP RELAY CONTROL CIRCUIT
When Monitored: With the ignition key on and battery voltage greater than 10 volts.
Set Condition: An open or shorted condition is detected in the fuel pump relay control
circuit.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
FUEL PUMP RELAY DEFECTIVE
FUEL PUMP RELAY CONTROL CIRCUIT OPEN
FUEL PUMP RELAY CONTROL CIRCUIT SHORT TO GROUND
FUEL PUMP RELAY WIRING HARNESS INTER DEF
FUEL PUMP RELAY WIRING HARNESS OBS DEF
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, actuate the Fuel Pump Relay.
Is the Fuel Pump Relay clicking?All
Ye s®Go To 2
No®Go To 4
2 Ignition On, Engine Not Running
With the DRB actuate the Fuel Pump Relay.
Wiggle the Wiring Harness from the Relay to the PCM.
Did the Fuel Pump Relay clicking stop or become erratic while wiggling the wires?All
Ye s®Repair Circuit as necessary where wiggling caused the clicking to
become erratic.
Perform Powertrain Verification Test VER-2A.
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-2A.
No®Test Complete.
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DRIVEABILITY
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