CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
4 Engine Running
With the DRB, read trouble codes.
Are there any Charging System trouble codes?All
Ye s®Refer to Symptom List for problems related to Charging.
Perform Powertrain Verification Test VER-3A.
No®Go To 5
5 Ignition Off
Using a Voltmeter, measure the voltage between the Generator Case and Battery (-)
side.
Caution: Ensure all Wires are clear of the engine's moving parts.
Start the engine.
Is the voltage above 0.4 volt?All
Ye s®Repair Generator Ground high resistance Generator Case to
Battery (-) side.
Perform Powertrain Verification Test VER-3A.
No®Go To 6
6 Ignition Off
Connect Voltmeter between the Generator (12V) B+ Terminal and the Battery (+)
side.
Caution: Ensure all Wires are clear of the engine's moving parts.
Start the engine.
Is the voltage above 0.4 volt?All
Ye s®Repair the B(+) Circuit for high resistance between the Generator
and Battery.
Perform Powertrain Verification Test VER-3A.
No®Go To 7
7 Turn engine off, ignition key on.
With the DRB, read Battery voltage and record.
Using a Voltmeter, measure Battery voltage B(+) to B(-) Terminal.
Record second voltage reading.
Compare the two voltage readings.
Is the voltage difference less than one volt?All
Ye s®Test Complete.
Perform Powertrain Verification Test VER-3A.
No®Go To 8
8 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Using a voltmeter, measure the fused B(+) at PCM.
Is the voltage within one volt of the DRB recorded reading?All
Ye s®Repair the B(+) Circuit for high resistance between the PCM and
the Battery.
Perform Powertrain Verification Test VER-3A.
No®Go To 9
25
CHARGING
* CHECKING CHARGING SYSTEM OPERATION WITH NO DTC'S Ð
Continued
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TEST ACTION APPLICABILITY
9 If there are no other potential causes remaining, the PCM is assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-3A.
26
CHARGING
* CHECKING CHARGING SYSTEM OPERATION WITH NO DTC'S Ð
Continued
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Symptom:
P-0106 BAROMETRIC PRESSURE OUT OF RANGE
When Monitored and Set Condition:
P-0106 BAROMETRIC PRESSURE OUT OF RANGE
When Monitored: With the ignition key on at less than 350 milliseconds and engine speed
at less than 255 RPM.
Set Condition: The PCM senses the voltage from the MAP sensor to be less than 2.196
volts but above 0.019 volt for 300 milliseconds
POSSIBLE CAUSES
MAP SENSOR 5V SUPPLY CIRCUIT OPEN
MAP SENSOR 5V SUPPLY CIRCUIT SHORT TO GROUND
MAP SENSOR SIGNAL CIRCUIT OPEN
MAP SENSOR SIGNAL CIRCUIT PARTIAL SHORT TO GROUND
MAP SENSOR WIRING HARNESS INTERMITTENT DEFECT
MAP SENSOR WIRING HARNESS OBSERVABLE DEFECT
MAP SENSOR DEFECTIVE
PCM DEFECTIVE (VOLTAGE HIGH)
PCM DEFECTIVE (VOLTAGE LOW)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the MAP Sensor voltage.
Is the voltage below 2.2 volts?All
Ye s®Go To 2
No®Go To 11
2 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Turn the ignition on, engine not running.
Note: Check connectors - Clean/repair as necessary.
Using a Voltmeter, measure voltage of the 5-Volt Supply Circuit at the Map Sensor
Connector.
Is the voltage above 4.5 volts?All
Ye s®Go To 3
No®Go To 7
27
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, with engine not running.
With the DRB, read the MAP Sensor voltage.
Is the voltage above 4.9 volts?All
Ye s®Replace the MAP Sensor.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Disconnect the MAP Sensor Electrical 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 resistance of the MAP Sensor Signal Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open MAP Sensor Signal Circuit between MAP Sensor
and PCM.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, with engine not running.
With the DRB, read the MAP Sensor voltage.
Is the voltage above 2.2 volts?All
Ye s®Repair the MAP Sensor Signal Circuit for a partial short to
ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 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.
7 Ignition Off
Disconnect the MAP Sensor Electrical 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 resistance of the 5-Volt Supply Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair the open 5-Volt Supply Circuit between MAP Sensor and
PCM Connectors.
Perform Powertrain Verification Test VER-2A.
28
DRIVEABILITY
P-0106 BAROMETRIC PRESSURE OUT OF RANGE ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Disconnect the MAP Sensor Electrical 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 5-Volt Supply Circuit to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the 5-Volt Supply Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 9
9 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, with engine not running.
With the DRB, read the MAP Sensor voltage.
Is the voltage above 2.2 volts?All
Ye s®Repair the MAP Sensor Signal Circuit for a partial short to
ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 10
10 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.
11 Ignition On, Engine Not Running
Wiggle the Wiring Harness from the MAP Sensor to the Powertrain Control Module.
Monitor the MAP Sensor voltage with the DRB, while wiggling the Wiring Harness.
Did the voltage go below 2.2 volts?All
Ye s®Repair Wiring as necessary where wiggling caused voltage drop.
Perform Powertrain Verification Test VER-2A.
No®Go To 12
12 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.
29
DRIVEABILITY
P-0106 BAROMETRIC PRESSURE OUT OF RANGE ÐContinued
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Symptom:
P-0107 MAP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P-0107 MAP SENSOR VOLTAGE TOO LOW
When Monitored: With engine rpm above 400 but less than 1500 and the TP Sensor
voltage less than 1.0 volt.
Set Condition: The MAP Sensor Signal voltage is below 1.2 volts at start, or below .02 volt
for 1.76 seconds with engine running.
POSSIBLE CAUSES
MAP SENSOR CONN/WIRING HARNESS INTERMITTENT DEF
MAP SENSOR CONN/WIRING HARNESS OBSERVABLE DEFECT
MAP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
MANIFOLD ABSOLUTE PRESSURE SENSOR DEFECTIVE
POWERTRAIN CONTROL MODULE DEFECTIVE
MAP SENSOR SIGNAL CIRCUIT OPEN
MAP SENSOR SIGNAL CKT SHORTED TO SENSOR GROUND CKT
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the MAP Sensor voltage.
Is the MAP Sensor voltage below 1.2 volts?All
Ye s®Go To 2
No®Go To 6
2 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Ignition on, engine not running.
Note: Check connectors - Clean/repair as necessary.
Use the DRB to read MAP Sensor voltage.
Is the MAP Sensor voltage above 4.0 volts?All
Ye s®Replace the MAP Sensor.
Perform Powertrain Verification Test VER-5A.
No®Go To 3
30
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the MAP Sensor Signal Circuit to
ground.
Is resistance below 5.0 ohms?All
Ye s®Repair MAP Sensor Signal Circuit shorted to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 4
4 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the MAP Sensor Signal Circuit to
Sensor Ground at MAP Sensor Connector.
Is resistance below 5.0 ohms?All
Ye s®Repair MAP Sensor Signal Circuit shorted to Sensor Ground
Circuit.
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.All
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
6 Ignition On, Engine Not Running
Wiggle MAP Sensor Connector & Harness.
Monitor the DRB display.
Was there any MAP Sensor voltage change?All
Ye s®Repair the Harness or Connector that caused the voltage change.
Perform Powertrain Verification Test VER-5A.
No®Go To 7
7 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.
31
DRIVEABILITY
P-0107 MAP SENSOR VOLTAGE TOO LOW ÐContinued
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Symptom:
P-0108 MAP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P-0108 MAP SENSOR VOLTAGE TOO HIGH
When Monitored: With engine rpm above 400 but less than 1500 and closed throttle.
Set Condition: The MAP Sensor Signal voltage is greater than 4.6.
POSSIBLE CAUSES
MAP SENSOR GROUND CIRCUIT OPEN
MAP SENSOR SIGNAL CIRCUIT OPEN
MAP SENSOR DEFECTIVE
MAP SENSOR WIRING HARN AND CONN INTERMITTENT DEF
MAP SENSOR WIRING HARNESS AND CONN OBSERVABLE DEF
PCM DEFECTIVE (MAP SENSOR VOLTAGE TOO HIGH)
TEST ACTION APPLICABILITY
1 Start the engine.
With the DRB, read the MAP Sensor voltage.
Is the MAP Sensor voltage above 4.6 volts?All
Ye s®Go To 2
No®Go To 6
2 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire between the Sensor Signal and Sensor Ground Circuits.
Turn ignition on, use the DRB to read the MAP Sensor voltage.
Is the voltage below 1.0 volt?All
Ye s®Replace the MAP Sensor.
Perform Powertrain Verification Test VER-5A.
No®Go To 3
3 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire between the Sensor Signal Circuit and an engine ground.
Ignition On.
Read the MAP Sensor voltage.
Is the MAP Sensor voltage below 1.0 volt?All
Ye s®Repair the open MAP Sensor Ground Circuit.
Perform Powertrain Verification Test VER-5A.
No®Go To 4
32
DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Disconnect the MAP Sensor Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test the MAP Sensor Signal Circuit for resistance.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open MAP Sensor Signal Circuit.
Perform Powertrain Verification Test VER-5A.
5 If 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.
6 Start the engine.
With the DRB, read the MAP Sensor voltage.
Wiggle MAP Sensor Connector and Harness.
Monitor the MAP Sensor voltage.
Was there any MAP Sensor voltage change when wiggled?All
Ye s®Repair the Harness or Connector that caused the voltage change.
Perform Powertrain Verification Test VER-5A.
No®Go To 7
7 Using the schematic as a guide inspect the Harness and Connectors.
Were any problems found?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
33
DRIVEABILITY
P-0108 MAP SENSOR VOLTAGE TOO HIGH ÐContinued
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Symptom:
P-0112 INTAKE AIR TEMP SENSOR VOLTAGE LOW
When Monitored and Set Condition:
P-0112 INTAKE AIR TEMP SENSOR VOLTAGE LOW
When Monitored: With the ignition on and the engine running.
Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes below .51 volt.
POSSIBLE CAUSES
IAT SEN WIRING HARNESS INTERMITTENT DEFECT
IAT SEN WRING HARNESS OBSERVABLE DEFECT
SENSOR SIGNAL CIRCUIT SHORT TO GROUND
SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GND CIRCUIT
IAT SENSOR VOLTAGE GREATER THAN 4.0 VOLTS
PCM DEFECTIVE (IAT SENSOR)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the IAT Sensor voltage.
Is the IAT Sensor voltage below 0.5 volt?All
Ye s®Go To 2
No®Go To 6
2 Ignition Off
Disconnect the IAT Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Ignition On, Engine Not Running
With the DRB, read the IAT Sensor voltage.
Is the IAT Sensor voltage above 4.0 volts?All
Ye s®Replace the IAT Sensor.
Perform Powertrain Verification Test VER-5A.
No®Go To 3
3 Ignition Off
Disconnect the IAT Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the PCM Connector.
Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the Sensor Signal Circuit to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Sensor Signal Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 4
34
DRIVEABILITY
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