engine CHRYSLER VOYAGER 2000 Diagnostic Manual

Symptom
P0172 -1/1 FUEL SYSTEM RICH
When Monitored and Set Condition:
P0172 -1/1 FUEL SYSTEM RICH
When Monitored: With the engine in closed loop mode, the ambient/battery temperature
above þ5 deg. C (20 deg. F) and altitude below 8000 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
the result is below a certain value for two trips, a freeze frame is stored, the MIL
illuminates and a trouble code is stored.
POSSIBLE CAUSES
FUEL PUMP MODULE DEFECTIVE
TPS VOLTAGE CHANGE NOT SMOOTH
TPS VOLTAGE <0.92V
FUEL INLET STRAINER PLUGGED
ECT SENSOR DEFECTIVE (OUT OF CALIBRATION)
MAP SENSOR DEFECTIVE (OUT OF CALIBRATION)
ENGINE MECHANICAL PROBLEM
FUEL FILTER/PRESSURE REGULATOR DEFECTIVE (HIGH)
FUEL FILTER/PRESSURE REGULATOR DEFECTIVE (LOW)
TEST ACTION APPLICABILITY
1 Turn ignition on.
With the DRB, read the DTC's.
Is the DTC Specific Good Trip Counter displayed and equal to zero?All
Ye s®Go To 2
No®Go To 14
2 Ignition On, Engine Not Running
With the DRB, read the TPS voltage.
While monitoring the DRB, slowly open and close the Throttle.
Is the voltage change smooth?All
Ye s®Go To 3
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
79
ProCarManuals.com

TEST ACTION APPLICABILITY
3 Ignition On, Engine Not Running.
With the DRB, read TP Sensor voltage. Throttle must be against stop.
Is the voltage 0.92 or less with the Throttle closed?All
Ye s®Go To 4
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
4 Turn ignition on.
With the DRB in sensors, read the ªEng Coolant Tmp Degº value.
Note: If engine coolant temperature is above 82ÉC (180ÉF), allow the engine
to cool until 62ÉC (150ÉF) is reached.
Start the Engine.
While monitoring the DRB, allow the engine to reach normal operating temperature
above 82ÉC (180ÉF).
Did the engine coolant temperature value reach 180ÉF or above?All
Ye s®Go To 5
No®Replace the Engine Coolant Temperature Sensor.
Perform Powertrain Verification Test VER-5A.
5 Turn ignition On.
With the DRB in sensors, read the ªEng Coolant Tmp Deg'' value
Note: If engine coolant temperature is above 82ÉC (180ÉF), allow the engine
to cool until 62ÉC (150ÉF) is reached.
Start the Engine.
While monitoring the DRB, allow the engine to reach normal operating temperature
above 82ÉC (180ÉF).
Was the coolant temperature value increase a smooth transition?All
Ye s®Go To 6
No®Replace the Engine Coolant Temperature Sensor.
Perform Verification Test VER-5A.
6 Turn ignition off.
Connect a Vacuum Gauge to a Manifold Vacuum source.
Start the engine.
Allow the engine to idle.
Note: If engine will not idle, maintain a constant RPM above idle.
Using the DRB in Sensors, read the MAP Sensor vacuum value.
Is the DRB reading within 19of the Vacuum Gauge reading?All
Ye s®Go To 7
No®Replace the MAP Sensor.
Perform Powertrain Verification Test VER-5A.
7Note: Engine must be at operating temp and in closed loop to perform this
test.
Start engine and run until operating temp and closed loop mode is reached.
With the DRB under System Tests, go to ªPurge Vapors Test''. Observe the Short
Term Adaptive value and press 3 to flow.
Note: Short Term Adaptive should change.
Did the Short Term Adaptive value change?All
Ye s®Go To 8
No®Refer to symptom *CHECKING EVAPORATIVE EMISSION
SYSTEM in the DRIVEABILITY category.
80
P0172 -1/1 FUEL SYSTEM RICH ÐContinued
ProCarManuals.com

TEST ACTION APPLICABILITY
8 Turn ignition off.
Warning: 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 pressure test port cap at the fuel rail test port. Connect a fuel pressure
gauge to the test port pressure fitting on the fuel rail.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/þ 5 psi.
Choose a conclusion that best matches your fuel pressure reading.All
Below Specification
Go To 9
Within Specification
Go To 13
Above Specification
Replace the fuel filter/pressure regulator.
Caution: Stop ALL Actuations.
9 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®Go To 10
10 Turn ignition off.
Warning: 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.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/169fuel line adapter tool #6539 between disconnected fuel line and
the fuel pump module.
Attach a fuel pressure test gauge to the ªT'' fitting on tool #6539.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/- 5 psi.
Is the fuel pressure within specification now?All
Ye s®Repair the restriction in the chassis fuel supply line between the
fuel tank and fuel rail.
No®Go to 11
Caution: Stop ALL Actuations.
81
P0172 -1/1 FUEL SYSTEM RICH ÐContinued
ProCarManuals.com

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
ProCarManuals.com

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.
83
DRIVEABILITY
ProCarManuals.com

TEST ACTION APPLICABILITY
8 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®Test Complete.
85
DRIVEABILITY
P-0201 INJECTOR #1 CONTROL CIRCUIT ÐContinued
ProCarManuals.com

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
ProCarManuals.com

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
87
DRIVEABILITY
P-0202 INJECTOR #2 CONTROL CIRCUIT ÐContinued
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com