key CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
6 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Go To 7
No®Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-1A.
7 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Return Tube for restriction between fuel Filter and Fuel Pump Module.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Replace restricted Fuel Tube.
Perform Powertrain Verification Test VER-1A.
No®Test Complete.
8 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Tee-In a Fuel Pressure Gauge into the Fuel Hose using tool #6433.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 psi for Gasoline.
Is the Fuel pressure below the specification ?ENGINE - 3.0L V6
Ye s®Go To 9
No®Test Complete.
9 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove adapter 6631 and reinstall Fuel Line.
Install adapter 6631 between Fuel Pump and Fuel Filter.
Connect Fuel Pressure Gauge to adapter 6631.
Key on.
With the DRB, actuate Fuel System.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 3.0L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 10
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* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
10 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pump Module.
Inspect the Fuel Pump Inlet Strainer.
Is the Inlet Strainer plugged?ENGINE - 3.0L V6
Ye s®Replace the Fuel Inlet Strainer.
Perform Powertrain Verification Test VER-1A.
No®Go To 11
11 Record the Fuel Pressure Gauge reading.
Ignition key off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pressure Gauge.
Remove Fuel Pressure Gauge Adapter 6433 and reconnect Fuel Line to Fuel Rail.
Install adapter 6631 between Fuel Filter Outlet and Chassis Fuel Supply Tube.
Connect Fuel Pressure Gauge to adapter 6631.
Ignition On, Engine Not Running.
With DRB, actuate the ASD Fuel System.
Record the Fuel Pressure Gauge reading.
Compare this reading with the previous reading.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 3.0L V6
Ye s®Repair restriction in Chassis Fuel Supply Line between Fuel
Filter and Fuel Rail.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
12 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.ENGINE - 3.0L V6
Repair
Replace Fuel Pump Module.
Perform Powertrain Verification Test VER-1A.
13 Ignition On, Engine Not Running
With DRB, read Throttle Position Sensor voltage.
Is the voltage above 1.5 volts?ENGINE - 3.0L V6
Ye s®Disconnect the TP Sensor Conn. Replace Throttle Position Sensor.
Perform Powertrain Verification Test VER-1A.
No®Go To 14
14 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note: Check connectors - Clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
With an Ohmmeter, measure the Fuel Pump Ground Circuit.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 15
No®Repair the open Fuel Pump Ground Circuit.
Perform Powertrain Verification Test VER-1A.
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STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
24 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Return Tube for restriction between fuel Filter and Fuel Pump Module.
Is there a restriction ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace restricted Fuel Tube.
Perform Powertrain Verification Test VER-1A.
No®Test Complete.
25 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Tee-In a Fuel Pressure Gauge into the Fuel Hose using tool #6433.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 PSI for Gasoline, 50 to 60 PSI for (E85) Ethanol.
Is the Fuel pressure below the specification ?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 26
No®Test Complete.
26 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove adapter 6631 and reinstall Fuel Line.
Install adapter 6631 between Fuel Pump and Fuel Filter.
Connect Fuel Pressure Gauge to adapter 6631.
Key On.
With the DRB, actuate Fuel System.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 27
27 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pump Module.
Inspect the Fuel Pump Inlet Strainer.
Is the Inlet Strainer plugged?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Inlet Strainer.
Perform Powertrain Verification Test VER-1A.
No®Go To 28
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* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
28 Record the Fuel Pressure Gauge reading.
Ignition Key Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pressure Gauge.
Install adapter 6631 between Fuel Filter Outlet and Chassis Fuel Supply Tube.
Connect Fuel Pressure Gauge to adapter 6631.
Ignition On, Engine Not Running.
With DRB, actuate the ASD Fuel System.
Record the Fuel Pressure Gauge reading.
Compare this reading with the previous reading.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Repair restriction in Chassis Fuel Supply Line between Fuel
Filter and Fuel Rail.
Perform Powertrain Verification Test VER-1A.
No®Go To 29
29 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Repair
Replace Fuel Pump Module.
Perform Powertrain Verification Test VER-1A.
30 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note: Check connectors - Clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
With an Ohmmeter, measure the Fuel Pump Ground Circuit.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 31
No®Repair the open Fuel Pump Ground Circuit.
Perform Powertrain Verification Test VER-1A.
31 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Ignition On , Engine Not Running.
With a Voltmeter, measure the Fuel Pump Relay Fused B(+) Circuit.
Is the voltage above 10.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 32
No®Repair the open Fuel Pump Relay Fused B(+) Circuit.
Perform Powertrain Verification Test VER-1A.
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* CHECKING THE FUEL SYSTEM ÐContinued
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Symptom:
* CHECKING THE IDLE AIR CONTROL MOTOR
POSSIBLE CAUSES
ENGINE NOT START AND STAY RUNNING
IAC MOTOR DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Hold the Engine Throttle 1/4 of the way down. Attempt to start the Engine.
Does the Engine start and stay running?All
Ye s®Go To 2
No®Refer to Symptom list for further diagnostic tests.
2 Ignition Off
Remove the IAC Motor.
Turn key on.
With the DRB in Actuator Tests, actuate the IAC Stepper Motor.
Observe the Pintle of the IAC Motor.
Is the IAC Motor Pintle moving in and out?All
Ye s®Test Complete.
No®Note: Ensure there are no IAC Motor related Trouble Codes
Before Making the following repair. Replace the IAC motor.
Perform Powertrain Verification Test VER-1A.
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TEST ACTION APPLICABILITY
2 Ignition Off.
Remove the Coil Secondary Cable from the Distributor.
Hold the Cable within 1/49of a good Ground.
Caution: Engine Controller damage may occur if more than 1/4(.
While cranking the Engine for 10 seconds, watch for spark.
Note: Consider 1 or 2 sparks as a No Spark condition.
Is there good spark?ENGINE - 3.0L V6
Ye s®Repair the Secondary Ignition: Distributor Cap, Rotor, Cables.
Perform Verification TEST VER-1A
No®Go To 3
3 Ignition Off
Remove the Coil Secondary Cable.
With an Ohmmeter, test the Coil Secondary Cable for resistance.
Is the resistance above 15 Kohms?ENGINE - 3.0L V6
Ye s®Replace the Coil Secondary Cable.
Perform Verification TEST VER-1A
No®Go To 4
4 Ignition Off.
Remove the Distributor Cap.
While cranking the Engine, watch for the Rotor to turn.
Did the Rotor turn when the Engine was cranked?ENGINE - 3.0L V6
Ye s®Go To 5
No®Go To 14
5 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Key On
With the DRB, actuate Ignition Coil.
With a Voltmeter, measure the ASD Output Circuit.
Is the voltage above 10 volts?ENGINE - 3.0L V6
Ye s®Go To 6
No®Go To 11
6 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Using an Ohmmeter, measure each Ignition Coil Primary Circuit for resistance.
Is the resistance below 2.0 ohms for each measurement?ENGINE - 3.0L V6
Ye s®Go To 7
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-1A.
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STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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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
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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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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Key on.
With the voltmeter, probe the TCC Solenoid Control Circuit at the PCM connector.
Is the voltage above 10.0 volts?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 4
No®Replace the TCC Solenoid.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Disconnect the Powertrain Control Module Connector.
Disconnect the TCC Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the TCC Solenoid Control Circuit from the TCC
Solenoid Connector to the PCM Connector.
Is the resistance below 5.0 ohms?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Go To 5
No®Repair the open TCC Solenoid Control Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Disconnect the Powertrain Control Module Connector.
Disconnect the TCC Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
With the DRB in ohmmeter mode, measure between the TCC Solenoid Control
Circuit and ground.
Is the resistance below 5.0 ohms?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Repair the TCC Solenoid Control Circuit 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.TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
7 Ignition On, Engine Not Running
With the DRB, erase codes.
Turn ignition off for 10 seconds, then turn ignition on.
With the DRB actuate the TCC Solenoid.
With the DRB, read codes.
Wiggle Wiring Harness from the Solenoid to PCM.
Does the TCC Solenoid Control Circuit code return?TRANSMISSION -
AUTOMATIC
3-SPD, 31TH
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
305
TRANSMISSION
P-0743 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT ÐContinued
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Symptom List:
ANTENNA FAILURE
COP FAILURE
EEPROM FAILURE
INTERNAL FAULTS
RAM FAILURE
SERIAL LINK INTERNAL
STACK OVERFLOW FAILURE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be ANTENNA FAILURE.
When Monitored and Set Condition:
EEPROM FAILURE
When Monitored: At ignition ON and during the SKIM programming process, which
programs SKIM's PIN the VIN, country code or additional keys.
Set Condition: This condition is set when an error occurs during programming the
SKIM's EEPROM. The other condition that causes this code to mature is an EEPROM I2C
link failure.
POSSIBLE CAUSES
SKIM INTERNAL DTC FAILURE
TEST ACTION APPLICABILITY
1Note: This trouble code indicates an internal SKIM fault.
With the DRBIIIt, read and record SKIM DTC's and then erase SKIM DTC's
Perform several key cycles, leaving the key on for a minimum of 30 seconds per cycle.
With the DRBIIIt, read SKIM trouble codes.
Did the SKIM Internal DTC return?All
Ye s®Replace the Sentry Key Immobilizer Module.
Perform the Powertrain Verification Test VER-7A.
No®Test Complete.
310
TRANSMISSION
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