check engine CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Is any terminal damaged, pushed out, or miswired?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the Ignition Coil #3 Primary Circuit for resistance.
Is the resistance below 2.0 ohms?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 5
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of Ignition Coil #3 Driver Circuit to ground.
Is the resistance below 5.0 ohms?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Repair the Ignition Coil #3 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 Ignition Off
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the Ignition Coil #3 Driver Circuit for resistance from
the PCM Connector to the Coil Connector.
Is the resistance below 5.0 ohms?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 7
No®Repair the open Ignition Coil #3 Driver Circuit.
Perform Powertrain Verification Test VER-2A.
7 Ignition Off
If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
P-0353 IGNITION COIL #3 PRIMARY CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
3 Turn off all accessories.
Start engine, allow engine to reach normal operating temperature.
Disconnect the Vacuum Supply Hose to the EGR Solenoid.
Connect a vacuum gauge to the disconnected hose.
Does the gauge read over 109of vacuum?All
Ye s®Go To 4
No®Repair the Vacuum Supply to the EGR Solenoid.
Perform VERIFICATION TEST VER-5A3.
4 Engine still running.
Reconnect the Vacuum Hose to the EGR Solenoid.
Disconnect the vacuum hose to the EGR Valve.
Connect a vacuum gauge to the disconnected hose.
Does the gauge pulsate?All
Ye s®Go To 5
No®Go To 7
5 While observing gauge, momentarily raise engine speed above 2000 rpm.
Did vacuum stabilize?All
Ye s®Go To 6
No®Replace EGR Valve Assembly.
Perform VERIFICATION TEST VER-5A3.
6 Remove the EGR Valve and inspect manifold and tube for restrictions.
Were any restrictions found?All
Ye s®Repair or replace as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Replace EGR Valve Assembly.
Perform VERIFICATION TEST VER-5A3.
7 Check for sizeable exhaust leak.
Were any leaks found?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Go To 8
8 Engine Running.
Disconnect Back Pressure Hose from Transducer.
Connect a pressure gauge to the Back Pressure Hose.
Is pressure gauge pulsating?All
Ye s®Replace EGR Assembly.
Perform VERIFICATION TEST VER-5A3.
No®Go To 9
9 Check EGR Back Mount. Check Valve tightness. Check EGR Valve Gasket.
Were any problems found?All
Ye s®Repair or replace as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Replace EGR Valve Assembly.
Perform VERIFICATION TEST VER-5A3.
132
DRIVEABILITY
P-0401 EGR SYSTEM FAILURE ÐContinued
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Symptom:
P-0403 EGR SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0403 EGR SOLENOID CIRCUIT
When Monitored: With the ignition key on and engine running and battery voltage > 10
volts.
Set Condition: The EGR solenoid control circuit is not in the expected state when
requested to operate by the PCM.
POSSIBLE CAUSES
EGR SOLENOID DEFECTIVE
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EGR SOLENOID CIRCUIT WIRING HARNESS INTER DEFECT
EGR SOLENOID CIRCUIT WIRING HARNESS OBSERVABLE DEF
EGR SOLENOID CONTROL CIRCUIT OPEN
EGR SOLENOID CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE (EGR SOL CKT)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the codes.
Is the Global Good Trip displayed and equal to 0?All
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Turn ignition on with engine not running.
Using the DRB, actuate the EGR Solenoid.
Using a Voltmeter, probe the Fused Ignition Switch Output Circuit at the EGR
Solenoid Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 3
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the EGR Solenoid.
Is the resistance between 25.0 and 50.0 ohms?All
Ye s®Go To 4
No®Replace the EGR Solenoid.
Perform Powertrain Verification Test VER-2A.
4 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the EGR Solenoid Control Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open EGR Solenoid Control Circuit.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the EGR Solenoid Connector.
Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the EGR Solenoid Control Circuit at the EGR Solenoid
Connector to a good ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the EGR Solenoid Control Circuit short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 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.
7 Ignition On, Engine Not Running
With the DRB, actuate the EGR Solenoid.
Wiggle Wiring Harness from the Solenoid to PCM.
Feel the EGR Assembly.
Does the EGR Solenoid stop actuating?All
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
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DRIVEABILITY
P-0403 EGR SOLENOID CIRCUIT ÐContinued
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Symptom:
P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored and Set Condition:
P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored: After engine warm up to 63 degrees C (147 degrees F), 180 seconds of
open throttle operation, at a speed greater than 30 Km/h (20 mph), with the engine at
1200-1700 rpm and MAP vacuum between 15.0 and 21.0 inches of mercury (Hg).
Set Condition: As catalyst efficiency deteriorates, the switch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. If at any point during the test the
switch ratio reaches a predetermined value a counter is incremented by one.
POSSIBLE CAUSES
EXHAUST LEAK
ENGINE MECHANICAL PROBLEM
CATALYTIC CONVERTER DEFECTIVE
UPSTREAM O2 SENSOR OLDER THAN DOWNSTREAM O2 SENSOR
CATALYST EFFICIENCY FAILURE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIPS counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the Catalyst Efficiency Failure does not exist or is an intermittent
problem.
With the DRB, read the FREEZE FRAME DATA.
With this screen, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME DATA pay particular attention to the fault setting
conditions, such as speed, temp, load, and map vacuum.
Does the Catalyst Efficiency Failure Reoccur?All
Ye s®Go To 3
No®The Catalytic Conveter Efficiency Failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
3 Start Engine and let idle.
Check for exhaust leaks between the Engine and the appropriate Downstream O2
Sensor.
Are there any exhaust leaks?All
Ye s®Repair or replace leaking exhaust parts as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Go To 4
136
DRIVEABILITY
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TEST ACTION APPLICABILITY
4NOTE: Check the exhaust for excessive smoke from internal oil or coolant
leaks.
Is there an oil or coolant consumption condition present?All
Ye s®Repair engine mechanical as necessary and replace Catalytic
Converter.
Perform VERIFICATION TEST VER-5A3.
No®Go To 5
5NOTE: A new Downstream O2 Sensor along with an aging Upstream O2
Sensor may cause this trouble code to set.
Review vehicle repair history.
Has the Downstream O2 Sensor been replaced without replacing the Upstream O2
Sensor?All
Ye s®Replace the appropriate Upstream Oxygen Sensor.
Perform VERIFICATION TEST VER-5A3.
No®Replace the Catalytic Converter.
Perform VERIFICATION TEST VER-5A3.
137
DRIVEABILITY
P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition On, Engine Not Running.
With the DRB, read codes.
With the DRB, actuate the Evap Purge Solenoid.
Wiggle Wiring Harness from the Solenoid to PCM.
Does the Evap Purge Solenoid Control Circuit code return?ALL
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 9
9 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 10
10 Check the freeze frame data to determine the conditions when code was set.
Attempt duplication of 'freeze frame' conditions for added diagnostics.
If there are no other possible causes remaining there is assumed to be an9intermit-
tent9problem with a Wiring Harness Connector or Wire.
View repair options.ALL
Repair
Visually inspect related Wire Harness Connectors and Harnesses.
Look for broken, bent, pushed out, or corroded terminals and for
chafed, pierced, or partiallly broken wire, respectively. Refer to
any hotlines or technical service bulletins that apply.
11 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?ALL
Ye s®Go To 12
No®Go To 18
12 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the Proportional Purge Solenoid.
Is the resistance 14.2 ohms +/- 1.4?ALL
Ye s®Go To 13
No®Replace the open Proportional Purge Solenoid.
Perform Powertrain Verification Test VER-5A.
145
DRIVEABILITY
P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
16 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using and Ohmmeter, measure the PWM Purge Sense Circuit PCM to Solenoid
Connector.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 17
No®Repair the open PWM Purge Sense Circuit.
Perform Powertrain Verification Test VER-5A.
17 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.
18 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
Wiggle Wiring Harness from the Solenoid to PCM.
Does the Evap Purge Solenoid Control Circuit code return?ALL
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 19
19 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 20
20 Check the freeze frame data to determine the conditions when code was set.
Attempt duplication of 'freeze frame' conditions for added diagnostics.
If there are no other possible causes remaining there is assumed to be an9intermit-
tent9problem with a Wiring Harness Connector or Wire.
View repair options.ALL
Repair
Visually inspect related Wire Harness Connectors and Harnesses.
Look for broken, bent, pushed out, or corroded terminals and for
chafed, pierced, or partiallly broken wire, respectively. Refer to
any hotlines or technical service bulletins that apply.
147
DRIVEABILITY
P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
1 Ignition Off
Raise the Drive Wheels off the ground.
Warning: Be sure to keep hands and feet clear of rotating wheels.
Start Engine.
With DRB, read the Vehicle Speed Sensor.
Put Transmission on any forward gear.
Does the DRB show above zero MPH?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 2
No®Go To 3
2 Ignition off.
Using the Schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?ENGINE -2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
3 Ignition Off
Disconnect the VSS Connector.
Note: Check connectors - Clean/repair as necessary.
Key On
Using a Voltmeter, probe the 8-Volt Power Supply Circuit.
Is the voltage above 7.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 4
No®Repair the open 8-volt Supply Circuit.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off
Disconnect the VSS Connector.
Note: Check connectors - Clean/repair as necessary.
Key On.
Using a Voltmeter, Probe the Vehicle Speed Sensor Signal.
Is the voltage above 4.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 5
No®Go To 11
5 Ignition Off
Disconnect the VSS Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire from the Sensor Signal to the Sensor Ground Circuit.
Key On
With the DRB, read the VSS Signal.
While observing display, tap other end of jumper to VSS Signal Circuit.
Does the display show more than 0 MPH?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 6
No®Go To 8
154
DRIVEABILITY
P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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TEST ACTION APPLICABILITY
6 Ignition Off
Remove the Vehicle Speed Sensor. Inspect the Speedometer Pinion Gear.
Is the Pinion Gear okay?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 7
No®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
7 If there are no potential causes remaining, the Vehicle Speed Sensor is assumed to be
defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Repair
Replace the VSS.
Perform Powertrain Verification Test VER-5A.
8 Ignition Off
Disconnect the VSS Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure between the Sensor Ground Circuit and Engine
Ground.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 9
No®Repair the open Sensor Ground Circuit.
Perform Powertrain Verification Test VER-5A.
9 Ignition Off
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Is any Terminal damaged, pushed out or miswired?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 10
10 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-5A.
11 Ignition Off
Disconnect the VSS Connector.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the VSS Signal Circuit from the PCM to the VSS
Connector.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.0L V6 w/o EATX
Ye s®Go To 12
No®Repair the open Speed Sensor Signal Circuit.
Perform Powertrain Verification Test VER-5A.
155
DRIVEABILITY
P-0500 NO VEHICLE SPEED SENSOR SIGNAL ÐContinued
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