air condition CHRYSLER VOYAGER 2000 Diagnostic Manual

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.
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DRIVEABILITY
P-0645 A/C CLUTCH RELAY CIRCUIT ÐContinued
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Symptom:
P-0703 BRAKE SWITCH STUCK PRESSED OR RELEASED
When Monitored and Set Condition:
P-0703 BRAKE SWITCH STUCK PRESSED OR RELEASED
When Monitored: With engine running. The PCM expects the signal to be high for 16
cycles while it monitors the brake switch signal during accel and decel modes.
Set Condition: After the vehicle speed increases, the PCM must accumulate 6 seconds
while delta throttle voltage is above 0.02 volt. The count is reset to zero whenever the
brake switch indicates a low signal.
POSSIBLE CAUSES
BRAKE SWITCH GROUND CIRCUIT OPEN
BRAKE SWITCH INTERNAL SHORT
BRAKE SWITCH SENSE CIRCUIT OPEN
BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND
PCM CONNECTOR OBSERVABLE DEFECT
PCM DEF (VOLTAGE HIGH)
PCM DEF (VOLTAGE LOW)
TEST ACTION APPLICABILITY
1 Ignition Off
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
Key on.
With a Voltmeter, measure the Brake Switch Sense Circuit at the Brake Switch
Connector.
Is the voltage above 9.0 volts?All
Ye s®Go To 2
No®Go To 5
2 Ignition Off
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Brake Switch Ground Circuit at the Brake Switch
Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Repair the Brake Switch Ground Circuit.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
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Symptom:
P-1195 SLOW 1/1 O2S DURING CATALYST MONITOR
When Monitored and Set Condition:
P-1195 SLOW 1/1 O2S DURING CATALYST MONITOR
When Monitored: With the engine running, coolant greater than 76 deg C (170 deg F),
open throttle, steady to slight increasing vehicle speed > 28 Km/h (18 mph) < 88 Km/h (55
mph), with a light load on the engine, for a period no less than five minutes.
Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39
volt to above 0.6 volt and back fewer times than required.
POSSIBLE CAUSES
OXYGEN SENSOR GROUND CIRCUIT OPEN
1/1 OXYGEN SENSOR CONNECTOR OBSERVABLE DEFECT
1/1 OXYGEN SENSOR DEFECTIVE
ENGINE FLUID CONSUMPTION
EXHAUST SYSTEM LEAKING
PCM CONNECTOR OBSERVABLE DEFECT
TEST ACTION APPLICABILITY
1 Start Engine
Note: Check the Exhaust for excessive smoke caused by oil or coolant
consumption.
Is there an oil or coolant consumption condition present?All
Ye s®Repair engine mechanical as necessary, and replace Upstream O2
Sensor.
Perform Powertrain Verification Test VER-5A.
No®Go To 2
2 Start Engine
Check the Exhaust System for leaks between Engine and Catalytic Converter.
Is there any Exhaust leak?All
Ye s®Repair or replace leaking Exhaust parts as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 3
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the Upstream Oxygen Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance from the O2 Sensor Ground Circuit to
a good ground.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the open Sensor Ground Circuit to the Upstream Oxygen
Sensor.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Disconnect the Upstream Oxygen Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Connectors and Terminals.
Is any Terminal damaged, pushed out or miswired?All
Ye s®Repair or replace as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 Ignition Off
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Connector.
Is the Connector condition OK?All
Ye s®Go To 6
No®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
6 If there are no potential causes remaining, the Upstream Oxygen Sensor is assumed
to be defective.
View repair options.All
Repair
Replace the Upstream Oxygen Sensor.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
P-1195 SLOW 1/1 O2S DURING CATALYST MONITOR 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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Symptom:
P-1294 TARGET IDLE NOT REACHED
When Monitored and Set Condition:
P-1294 TARGET IDLE NOT REACHED
When Monitored: Engine idling more than 2.8 seconds and coolant temp greater than 70
degrees C (160 degrees F). For an automatic transmission, in drive mode. There must not
be a MAP Sensor or TP Sensor or speed sensor trouble code.
Set Condition: Engine idle is > 200 RPM above target idle speed or less than 100 RPM
below target idle speed for 20 seconds. Two consecutive failures in a row will store this
trouble code.
POSSIBLE CAUSES
ENG VACUUM HOSES AND COMPONENTS LEAKS
THROTTLE BODY DEFECTIVE
THROTTLE PLATE/LINKAGE NOT IN CORRECT POS
IAC WIRING HARNESS INTERMITTENT DEFECT
IAC WIRING HARNESS OBSERVABLE DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Does the engine exhibit a start and stall condition?All
Ye s®Go To 2
No®Go To 4
2 Ignition Off
Perform minimum air flow test that is described in the service information.
Is the idle RPM within the range shown in the chart?All
Ye s®Test Complete.
No®Go To 3
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition off.
Remove the Throttle Body per service information procedure.
Note: Clean Throttle Body in a well ventilated area and wear rubber gloves.
While holding the Throttle open spray entire Throttle Body Bore with Mopar parts
cleaner.
Using a soft scuff pad, clean the Throttle Body Bore and Throttle Plate.
Using compressed air, dry the Throttle Body and install Throttle Body on Manifold.
Reconnect IAC Motor Connector and reset the IAC Motor Steps with the DRB.
Start engine and let idle.
With the DRB, actuate the minimum air flow.
Is the idle RPM within the range shown in the chart? Refer to the Service
Information.All
Ye s®Test Complete.
No®Replace the Throttle Body.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Start engine, allow engine idle to stabilize for 60 seconds.
With the DRB, read target idle and engine RPM.
Is the engine RPM within +200/-100 RPM of target idle?All
Ye s®Go To 5
No®Go To 8
5 Ignition Off
Remove the IAC Motor from the housing.
Turn Ignition on with Engine Not Running.
With the DRB, actuate the IAC Stepper Motor.
Wiggle the Wiring Harness from the IAC Motor to the PCM.
Did the IAC stop operating at any time?All
Ye s®Repair the Harness or Connectors as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 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®Go To 7
7 Ignition On, Engine Not Running
Check Throttle Plate and Linkage for a binding condition.
The Throttle Linkage must be free and the Throttle Plate at the idle
position.
Ensure Throttle Plate is fully closed and against its stop.
Is the Throttle Plate and Linkage okay?All
Ye s®Test Complete.
No®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
P-1294 TARGET IDLE NOT REACHED ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Start engine, allow engine idle to stabilize for 60 seconds.
With the engine running at idle, the DRB in Systems Test, perform the IAC wiggle
test.
The idle speed should raise and lower with the display.
Does the RPM raise and lower correctly?All
Ye s®Go To 9
No®Refer to symptom P-0505 IDLE AIR CONTROL MOTOR CIR-
CUITS in the DRIVEABILITY category.
9 Ignition Off
Start engine, allow engine idle to stabilize for 60 seconds.
Check engine Vacuum Hoses and Components for vacuum leaks.
Ensure PCV Valve is the correct part and is operating correctly.
Were any problems found?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 10
10 Ignition Off
Remove the IAC Motor from the housing.
Turn Ignition on with Engine Not Running.
With the DRB, actuate the IAC Stepper Motor.
Wiggle the Wiring Harness from the IAC Motor to the PCM.
Did the IAC stop operating at any time?All
Ye s®Repair the Harness or Connectors as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 11
11 Ignition On, Engine Not Running
Check Throttle Plate and Linkage for a binding condition.
The Throttle Linkage must be free and the Throttle Plate at the idle
position.
Ensure Throttle Plate is fully closed and against its stop.
Is the Throttle Plate and Linkage okay?All
Ye s®Go To 12
No®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
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-5A.
No®Test Complete.
182
DRIVEABILITY
P-1294 TARGET IDLE NOT REACHED ÐContinued
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Symptom:
P-1297 NO CHANGE IN MAP FROM START TO RUN
When Monitored and Set Condition:
P-1297 NO CHANGE IN MAP FROM START TO RUN
When Monitored: Engine is idling with a stable RPM (RPM fluctuation < 64 RPM) and
the vehicle is not moving.
Set Condition: Too small a difference is seen between barometric pressure at ignition on
and manifold vacuum.
POSSIBLE CAUSES
MAP SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
MAP SENSOR WIRING HARNESS INTERMITTENT DEF
VACUUM PORTS RESTRICTED OR DEFECTIVE
MANIFOLD ABSOLUTE PRESSURE SENSOR RESTRICTED
MAP SENSOR DEFECTIVE (A)
MAP SENSOR DEFECTIVE (B)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes
Is9MAP Sensor voltage too low9code set?All
Ye s®Refer to symptom P-0107 MAP SENSOR VOLTAGE TOO LOW in
the DRIVEABILITY category.
No®Go To 2
2 With the DRB erase Codes.
Ignition On, Engine Not Running
Start engine and allow engine to idle for 30 seconds.
With the DRB read codes.
Does the DRB show9No change in MAP from start to run9?All
Ye s®Go To 3
No®Go To 6
3 Ignition on, with engine not running.
Disconnect MAP Sensor.
Note:Check connectors - clean/repair as necessary.
Ignition on, with engine not running.
Using a Voltmeter, measure the MAP Sensor 5-Volt Supply Circuit at the MAP
Sensor Connector.
Is the voltage above 4.0 volts?All
Ye s®Go To 4
No®Repair the open MAP Sensor 5-volt Supply Circuit.
Perform Powertrain Verification Test VER-5A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition off.
Remove MAP Sensor and inspect for Vacuum restrictions.
Check connectors - Clean/repair as necessary.
Was there a restriction?All
Ye s®Remove the restriction and reinstall the MAP Sensor
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 If there are no potential causes remaining, the MAP Sensor is assumed to be
defective.
View repair options.All
Repair
Replace the MAP Sensor.
Perform Powertrain Verification Test VER-5A.
6 Engine must be running.
While monitoring the DRB display, snap the Throttle open and closed.
Did the vacuum drop rapidly below 1.09?All
Ye s®Go To 7
No®Go To 8
7 Engine must be running.
With the DRB,set the engine speed to 1500 RPM.
With the engine RPM at 1500, read MAP sensor voltage.
While monitoring the voltage, wiggle the wiring from the MAP Sensor to PCM.
Did the engine stall or voltage become erratic?All
Ye s®Repair the Wiring or Connector defective between the Map
Sensor and the PCM.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
8 Engine must be running.
With the DRB,set the engine speed to 1500 RPM.
With the engine RPM at 1500, read MAP sensor voltage.
While monitoring the voltage, wiggle the wiring from the MAP Sensor to PCM.
Did the engine stall or voltage become erratic?All
Ye s®Repair the Wiring or Connector defective between the Map
Sensor and the PCM.
Perform Powertrain Verification Test VER-5A.
No®Go To 9
9 Ignition Off
Remove the MAP Sensor and inspect condition of Intake Manifold and MAP Sensor
Vacuum Ports.
Check connectors - Clean/repair as necessary.
Is there a restriction or defect in the Vacuum Ports?All
Ye s®Repair the restricted or defective Vacuum Ports.
Perform Powertrain Verification Test VER-5A.
No®Go To 10
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DRIVEABILITY
P-1297 NO CHANGE IN MAP FROM START TO RUN ÐContinued
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