fuse CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
21 Ignition Off.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #1.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #4.
Note: Check connectors - Clean/repair as necessary.
Note: Either Spark Plug #1 or #4 will not produce a good spark.
Remove Spark Plugs #1 and #4.
Inspect and determine which Spark Plug needs replacement.
View repair options.ENGINE - 2.0L
and 2.4L I-4 DOHC
Repair
Replace the Spark Plug that will not produce a spark.
Perform Powertrain Verification Test VER-1A.
22 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect 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-1A.
No®Go To 23
23 Ignition On, Engine Not Running.
With the DRB, actuate Ignition Coil #1.
With a Voltmeter, measure the ASD Relay Output Circuit.
Is the voltage above 10 volts?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Replace Ignition Coil.
Perform Powertrain Verification Test VER-1A.
No®Go To 24
24 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, measure the ASD Relay Output Circuit for resistance to ground
at the Relay.
Is the resistance below 5.0 ohms?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Go To 25
No®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
25 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit, cavity B in ASD Relay Connector.
Is the Voltage above 10 volts?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Replace the Auto Shutdown Relay.
Perform Verification Test VER-1A
No®Repair open Fused B(+).
Perform Verification TEST VER-1A
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STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
30 Ignition On, Engine Not Running.
With the DRB, actuate Ignition Coil #1.
With a Voltmeter, measure the ASD Relay Output Circuit.
Is the voltage above 10 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Replace Ignition Coil.
Perform Powertrain Verification Test VER-1A.
No®Go To 31
31 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, measure the ASD Relay Output Circuit for resistance to ground
at the Relay.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 32
No®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
32 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit, cavity B in ASD Relay Connector.
Is the Voltage above 10 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Replace the Auto Shutdown Relay.
Perform Verification Test VER-1A
No®Repair open Fused B(+).
Perform Verification TEST VER-1A
295
STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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Symptom:
* NO CRANK CONDITION
POSSIBLE CAUSES
BATTERY CIRCUIT RESISTANCE TOO HIGH
FUSED B(+) CIRCUIT OPEN
STARTER RELAY CONTROL CIRCUIT OPEN
STARTER RELAY OUTPUT CIRCUIT OPEN
CRANKSHAFT NOT ABLE TO ROTATE
STARTER MOTOR DEFECTIVE
PCM DEFECTIVE (NO CRANK CONDITION)
STARTER RELAY DEFECTIVE (RESISTANCE <=100 OHMS)
STARTER RELAY DEFECTIVE (RESISTANCE ABOVE 100 OHMS)
IGNITION SWITCH OUTPUT CIRCUIT OPEN
PARK/NEUTRAL SWITCH DEFECTIVE
TEST ACTION APPLICABILITY
1Note: Ensure the SKIM has proper communication and that there are no
SKIM DTC's present before continuing.
Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Warning: The Transmission must be in Park and the Parking Brake must be
on for the next step.
Warning: The engine may be cranked in the next step. Keep away from
moving parts.
Briefly connect a jumper wire between Starter Relay Output and Fused B(+)
Circuits.
Did the Starter Motor crank the Engine?All
Ye s®Go To 2
No®Go To 9
2 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit.
Is the voltage above 11.6 volts?All
Ye s®Go To 3
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
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STARTING
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TEST ACTION APPLICABILITY
8 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-1A.
9 Ignition Off.
Ensure the Transmission is in Park.
With the DRB, read the Park/Neutral Position Switch.
Does the Switch show Park?All
Ye s®Go To 10
No®Repair Park/Neutral Switch.
Perform Powertrain Verification Test VER-1A.
10 Ignition Off
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Warning: The Engine may be cranked in the next step. Keep away from
moving parts.
Warning: The engine may be cranked in the next step. Keep away from
moving parts.
Briefly connect a jumper wire between Starter Relay Output and Fused B(+)
Circuits.
Did the Starter Solenoid click when the jumper wire was connected?All
Ye s®Go To 11
No®Go To 15
11 Ignition Off
Check the Battery Cables for high resistance. (Use Service Manual procedure.)
Did either Battery Circuit have a voltage drop greater than 0.2 volt?All
Ye s®Repair the Battery Circuit for high resistance.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
12 Ignition Off
Attempt to manually rotate the Crankshaft 360 degrees.
Is the Crankshaft able to rotate 360 degrees?All
Ye s®Go To 13
No®Repair the Engine mechanical problem as necessary.
Perform Powertrain Verification Test VER-1A.
13 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit.
Is the voltage above 11.6 volts?All
Ye s®Go To 14
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
298
STARTING
* NO CRANK CONDITION ÐContinued
ProCarManuals.com

TEST ACTION APPLICABILITY
14 Ignition Off.
Disconnect Starter Relay Output Wire from the Starter Solenoid.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure Starter Relay Output Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 19
No®Repair open Starter Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
15 Ignition Off
Check the Battery Cables for high resistance. (Use Service Manual procedure.)
Did either Battery Circuit have a voltage drop greater than 0.2 volt?All
Ye s®Repair the Battery Circuit for high resistance.
Perform Powertrain Verification Test VER-1A.
No®Go To 16
16 Ignition Off
Attempt to manually rotate the Crankshaft 360 degrees.
Is the Crankshaft able to rotate 360 degrees?All
Ye s®Go To 17
No®Repair the Engine mechanical problem as necessary.
Perform Powertrain Verification Test VER-1A.
17 Ignition Off.
Disconnect Starter Relay Output Wire from the Starter Solenoid.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure Starter Relay Output Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 18
No®Repair open Starter Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
18 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit.
Is the voltage above 11.6 volts?All
Ye s®Go To 19
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
299
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* NO CRANK CONDITION ÐContinued
ProCarManuals.com

Symptom:
P-0740 TORQUE CONV CLUTCH, NO RPM DROP AT LOCKUP
When Monitored and Set Condition:
P-0740 TORQUE CONV CLUTCH, NO RPM DROP AT LOCKUP
When Monitored: Continuously when no matured or maturing Trouble Code and throttle
position >10% and constant for 4.4 seconds before TCC engagement requested: No TCC
solenoid circuit, any cam/crank-related code, VSS, any TPS-related code and Battery
voltage >11.0
Set Condition: Torque Converter malfunctions that are detected are the FTC not locking
up properly when desired, and the torque converter not unlocking properly when desired.
3 consecutive test failures over one trip will store the code. 2 bad trips will set the code.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
DIFF, SHAFT, OR GEARS DEFECTIVE
TCC SOL DEFECTIVE
TORQUE CONVERTER ASSEMBLY DEF OR TCC SOL STUCK
TRANSMISSION FLUID DIRTY OR LEVEL LOW
VEHICLE CONFIGURATION NON-STANDARD
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 2
No®Test Complete.
2 Ignition Off
At the9Cooler In9port puta0to300PSIgauge using a9T9. Ensure line is long
enough to reach in driver's side of vehicle so gauge can be monitored while driving.
Road test vehicle. Gear select in drive. While monitoring DRB, achieve 50 MPH.
While doing this, notice the gauge will read around 15 PSI until lockup is achieved
in 3rd gear. If the TCC Solenoid is operating properly, the gauge pressure will
fluctuate when lockup is achieved.
Did gauge fluctuate?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 3
No®Refer to service instructions for proper service procedure on
Torque Converter Assembly or stuck TCC Solenoid and repair as
necessary.
Perform Powertrain Verification Test VER-5A.
302
TRANSMISSION
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TEST ACTION APPLICABILITY
3 Ignition Off
Check Transmission Fluid level and ensure it is clear of any debris.
Is the Transmission Fluid okay?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 4
No®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Disconnect the TCC Solenoid connector.
Note: Check connectors - Clean/repair as necessary.
Turn key on.
Use a Voltmeter in the following step.
Using a Voltmeter, measure the Fused Ignition Switch Output Circuit at Solenoid
Connector.
Is the voltage above 10.0 volts?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 5
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Disconnect the TCC Solenoid connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure across the Solenoid for resistance.
Was resistance between 30.0 and 50.0 ohms?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 6
No®Replace TCC Solenoid.
Perform Powertrain Verification Test VER-5A.
6 Drive Vehicle
Maintain 50 MPH per DRB. Wait 10 seconds in lockup. Record Engine RPM.
Was engine RPM 2200 +/- 50 RPM?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 7
No®Inspect Differential, Output Shaft, or Gear Box. Refer to service
instructions for proper diagnosis.
Perform Powertrain Verification Test VER-5A.
7 Ignition Off
Remove VSS.
Note: Check connectors - Clean/repair as necessary.
Inspect sensor and gear for damage, also improper wheel size.
Were any problems found?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
303
TRANSMISSION
P-0740 TORQUE CONV CLUTCH, NO RPM DROP AT LOCKUP ÐContinued
ProCarManuals.com

Symptom:
P-0743 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0743 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT
When Monitored: With the ignition key on.
Set Condition: An open or shorted condition is detected in the Torque Converter Clutch
Solenoid Control Circuit.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
TORQUE CONVERTER CLUTCH SOLENOID DEFECTIVE
TCC SOLENOID CIRCUIT W/H INTERMITTENT DEFECT
TCC SOLENOID CIRCUIT W/H OBSERVABLE DEFECT
TCC SOLENOID CONTROL CIRCUIT OPEN
TCC SOLENOID CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE (TCC SOLENOID CONTROL CIRCUIT)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Disconnect the TCC Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Key on.
With the Voltmeter, probe the voltage of the Fused Ignition Switch Output Circuit at
Solenoid Connector.
Is the voltage above 10.0 volts?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 3
No®Repair the open Fused Ignition Switch Output Circuit..
Perform Powertrain Verification Test VER-5A.
304
TRANSMISSION
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9.0 CONNECTOR PINOUTS
A/C COMPRESSOR CLUTCH - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 C3 18DB/BK A/C CLUTCH COMPRESSOR RELAY OUTPUT
2 Z1 18BK GROUND
AMBIENT TEMPERATURE SENSOR - GRAY 2 WAYCAV CIRCUIT FUNCTION
1 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 20BK/LB SENSOR GROUND
AMBIENT TEMPERATURE SENSOR (SENSOR SIDE) 2 WAYCAV CIRCUIT FUNCTION
1 - AMBIENT TEMPERATURE SENSOR SIGNAL
2 - SENSOR GROUND
BRAKE LAMP SWITCH - GRAY 6 WAYCAV CIRCUIT FUNCTION
1 K29 20WT/PK BRAKE SWITCH SENSE
2 Z1 20BK GROUND
3 V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
4 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
5 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
6 F32 18PK/DB FUSED B(+)
C
O
N
N
E
C
T
O
R
P
I
N
O
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T
S
333
CONNECTOR PINOUTS
ProCarManuals.com

BRAKE SHIFT INTERLOCK SOLENOID (EXCEPT BUILT-UP EXPORT)-2WAYCAV CIRCUIT FUNCTION
1 K29 20WT/PK RED BRAKE WARNING LAMP DRIVER
2 F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF)
CAMSHAFT POSITION SENSOR - BLACK 3-WAYCAV CIRCUIT FUNCTION
1 K7 18OR 8V SUPPLY
2 K4 18BK/LB SENSOR GROUND
3 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
CLOCKSPRING C1 - YELLOW 2 WAYCAV CIRCUIT FUNCTION
1 R43 18BK/LB DRIVER AIRBAG LINE 1
2 R45 18DG/LB DRIVER AIRBAG LINE 2
CLOCKSPRING C2 - NATURAL 5 WAYCAV CIRCUIT FUNCTION
1 X3 20BK/RD HORN RELAY CONTROL SENSE
2 X10 20RD/WT (RADIO RE-
MOTE CONTROL)RADIO MUX
3 Z2 20BK/LG (SPEED CON-
TROL)GROUND
4 V37 20RD/LG (SPEED
CONTROLSPEED CONTROL SWITCH SIGNAL
5 X20 20RD/BK (RADIO RE-
MOTE CONTROL)RADIO CONTROL MUX
C
O
N
N
E
C
T
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P
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334
CONNECTOR PINOUTS
ProCarManuals.com