check engine CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
11Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?All
Ye s®Replace the Fuel Inlet Strainer.
No®Go To 12
12 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.All
Repair
Replace the Fuel Pump Module
13 Check for any of the following conditions/mechanical problems.
ENGINE VACUUM Ð must be at least 13 inches in neutral
ENGINE VALVE TIMING Ð must be within specifications
ENGINE COMPRESSION Ð must be within specifications
ENGINE EXHAUST SYSTEM Ð must be free of any restrictions or leaks.
ENGINE PVC SYSTEM Ð must flow freely
TORQUE CONVERTER STALL SPEED Ð must be within specifications
POWER BRAKE BOOSTER Ð no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR Ð plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?All
Ye s®Repair as necessary.
Perform FUEL SYSTEM/MISFIRE MONITOR VERIFICATION
TEST
No®Test Complete.
14 The conditions required to set the DTC are no longer present.
With the DRB read and record the freeze frame data and the ªFuel System Similar
Conditions Window'' data.
Utilize the data and try to duplicate the operating conditions at which the DTC was
set. Pay particular attention to the ECT and RPM for added diagnostics.
Note: Refer to any TSB's that may apply to the symptom.
Test Complete
Repair
Test Complete.
82
P0172 -1/1 FUEL SYSTEM RICH ÐContinued
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Symptom:start here
P-0201 INJECTOR #1 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0201 INJECTOR #1 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 DEFECTIVE
INJECTOR #1 DRIVER CIRCUIT OPEN
INJECTOR #1 DRIVER CIRCUIT SHORTED TO GROUND
POWERTRAIN CONTROL MODULE DEFECTIVE
INJECTOR #1 DRIVER CIRCUIT SHORT TO GROUND
INJECTOR #1 DRIVER CIRCUIT SHORT TO GROUND (PCM)
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
Disconnect the Injector #1 Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #1.
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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Symptom:
P-0202 INJECTOR #2 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0202 INJECTOR #2 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 DEFECTIVE
INJECTOR #2 DRIVER CIRCUIT OPEN
INJECTOR #2 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 #2 Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #2.
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.
86
DRIVEABILITY
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TEST ACTION APPLICABILITY
3Note: It may be necessary to remove the Intake Plenum in the following
steps.
Ignition Off
Disconnect the Injector #2 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 Circuit 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
Disconnect the Injector #2 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Use an Ohmmeter in the following step.
Measure the Injector #2 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 #2 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Disconnect the Injector #2 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 #2 Driver Circuit to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Injector #2 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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DRIVEABILITY
P-0202 INJECTOR #2 CONTROL CIRCUIT ÐContinued
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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.
89
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
90
DRIVEABILITY
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.
92
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
93
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.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Disconnect Injector #5 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 #5 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 #5 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Disconnect Injector #5 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 #5 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 #5 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 PCM 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 PCM.
Perform Powertrain Verification Test VER-5A.
7 Ignition Off
Using the schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?ENGINE - 3.0L,
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-5A.
No®Go To 8
8 Engine Running
Wiggle Wiring Harness from the Injector to the PCM.
Does the engine miss or stall?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary where wiggling caused the problem to
appear.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
96
DRIVEABILITY
P-0205 INJECTOR #5 CONTROL CIRCUIT ÐContinued
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