torque CHRYSLER VOYAGER 2000 Diagnostic Manual

TABLE OF CONTENTS - Continued
SPEED CONTROL
P-1595 SPEED CONTROL SOLENOID CIRCUITS...........................256
P-1683 SPEED CONTROL POWER RELAY OR S/C 12V DRIVER..............256
SPEED CONTROL BRAKE SWITCH OUTPUT..............................261
SPEED CONTROL DENIED MESSAGE....................................263
SPEED CONTROL ON/OFF SWITCH......................................264
* CHECKING SPEED CONTROL OPERATION..............................266
STARTING
*9NO RESPONSE9CONDITION..........................................272
* CHECKING THE CAM AND CRANK SENSORS............................276
* CHECKING THE ENGINE MECHANICAL SYSTEMS........................277
* CHECKING THE FUEL SYSTEM........................................278
* CHECKING THE IDLE AIR CONTROL MOTOR.............................287
* CHECKING THE SECONDARY IGNITION SYSTEM.........................288
* NO CRANK CONDITION...............................................296
* START AND STALL CONDITION.........................................301
TRANSMISSION
P-0740 TORQUE CONV CLUTCH, NO RPM DROP AT LOCKUP...............302
P-0743 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT................304
P-1899 PARK/NEUTRAL SWITCH STUCK IN PARK OR IN GEAR..............307
ANTENNA FAILURE....................................................310
COP FAILURE.........................................................310
EEPROM FAILURE.....................................................310
INTERNAL FAULTS.....................................................310
RAM FAILURE.........................................................310
SERIAL LINK INTERNAL................................................310
STACK OVERFLOW FAILURE............................................310
SENTRY KEY IMMOBILIZER SYSTEM
PCM STATUS FAILURE.................................................311
ROLLING CODE FAILURE...............................................311
SERIAL LINK EXTERNAL FAULT..........................................311
TRANSPONDER COMMUNICATION FAILURE..............................313
TRANSPONDER ID MISMATCH..........................................313
TRANSPONDER RESPONSE MISMATCH..................................313
VIN MISMATCH........................................................315
VERIFICATION TESTS
VERIFICATION TESTS..................................................317
8.0 COMPONENT LOCATIONS..............................................323
8.1CONTROL MODULES AND PDC.....................................323
8.2CONTROLS & SOLENOIDS.........................................323
8.3DATA LINK CONNECTOR..........................................327
8.4SENSORS.......................................................327
8.5FUEL SYSTEM...................................................330
8.6SWITCHES......................................................331
8.7SPECIFICATIONS.................................................332
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TABLE OF CONTENTS - Continued
ENGINE STARTER MOTOR RELAY.......................................347
FRONT BLOWER MOTOR RELAY........................................347
FUEL HEATER RELAY (DIESEL)..........................................347
FUEL PUMP RELAY (GAS)..............................................347
HIGH BEAM RELAY....................................................347
HORN RELAY.........................................................347
LOW BEAM RELAY....................................................348
PARK LAMP RELAY....................................................348
TRANSMISSION CONTROL RELAY (EATX).................................348
WIPER HIGH/LOW RELAY...............................................348
WIPER ON RELAY.....................................................348
POWERTRAIN CONTROL MODULE C1 - BLACK 40 WAY.....................349
POWERTRAIN CONTROL MODULE C2 - GRAY 40 WAY......................350
RADIATOR FAN NO. 1 - BLACK 2 WAY....................................350
RADIATOR FAN NO 2 - BLACK 2 WAY....................................351
RADIATOR FAN RELAY - BLACK 4 WAY...................................351
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY......................351
THROTTLE POSITION SENSOR (2.0L) - BLACK 3 WAY......................351
THROTTLE POSITION SENSOR (EXCEPT 2.0L) - NATURAL 3 WAY............352
TORQUE CONVERTER CLUTCH SOLENOID (ATX)-3WAY..................352
TRANSMISSION CONTROL MODULE - BLACK 60 WAY......................353
TRANSMISSION RANGE SENSOR - GRAY 10 WAY.........................354
TRANSMISSION SOLENOID/PRESSURE SWITCH - BLACK 8 WAY............354
VEHICLE SPEED CONTROL SERVO - BLACK 4 WAY........................354
VEHICLE SPEED SENSOR (EXCEPT 3.3L/3.8L) - BLACK 3 WAY..............354
10.0 SCHEMATIC DIAGRAMS................................................355
10.12000 GS 2.0L AND 2.4L ENGINES...................................355
10.22000 GS 3.0L ENGINE...........................................356
10.32000 GS 3.3L and 3.8L ENGINES................................................................357
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TEST ACTION APPLICABILITY
11 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 12
12 Turn ignition off.
Warning: The fuel system is under 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.
Disconnect the fuel supply line at the fuel rail.
Connect fuel line adapter #6539(5/169) or #6631 (3/89) to the disconnected fuel supply
line. Insert the other end of the adapter into a graduated container.
Caution: Do not operate the fuel pump for more than 7 seconds in the next
step. Fuel pump module reservoir may run empty and damage to the fuel
pump may result.
Specification: A good fuel pump will deliver at least 1/4 liter of fuel in 7
seconds.
With the DRB, actuate the ASD Fuel System test for 7 seconds.
Is the fuel pump capacity within specification?All
Ye s®Test Complete.
No®Check for a kinked/damaged fuel supply line between the fuel
tank and fuel rail. If OK, replace the fuel filter/pressure regulator.
Caution: Stop ALL Actuations.
13 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 Windowº 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.
78
DRIVEABILITY
P-0171±1/1 FUEL SYSTEM LEAN ÐContinued
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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
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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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TEST ACTION APPLICABILITY
12 Engine Off.
Connect a suitable engine analyzer to the engine.
Allow the Engine to idle.
NOTE: If the Engine will not idle, maintain a constant RPM above idle.
NOTE: Set the scope to read display or parade pattern.
Remove any spark plug wire.
Observe the Secondary KV Line.
Is the open secondary voltage at least 25 KV?All
Ye s®Go To 13
No®Replace the Ignition Coil.
Perform VERIFICATION TEST VER-5A2.
13 Engine Off.
Connect a suitable engine analyzer to the engine.
Allow the Engine to idle.
NOTE: If the Engine will not idle, maintain a constant RPM above idle.
NOTE: Set the scope to read display or parade pattern.
Follow the equipment manufacturer's procedure for pattern analysis.
Is the secondary ignition pattern OK?All
Ye s®Go To 14
No®Repair the indicated component in the Secondary Ignition Sys-
tem.
Perform VERIFICATION TEST VER-5A2.
14 The following are possible causes for mis-fire:
Injector harness connectors, ignition coil circuit, spark plug, mechanical engine
problem, PCM power grounds, irregular cam and crank signal, injectors, restricted
exhaust, intake restriction, PCM, Evap System, EGR System, damaged trigger
wheel, and
accessory drive belts.
Do any of the above causes exist?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A2.
No®Go To 15
15The following additional items should be checked as possible mechanical
problems:
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions
ENGINE PCV SYSTEM - must flow freely
ENGINE DRIVE SPROCKETS - must be properly positioned
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A2.
No®Test Complete.
103
DRIVEABILITY
P-0300 MULTIPLE CYLINDER MIS-FIRE ÐContinued
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TEST ACTION APPLICABILITY
12 Engine Off.
Connect a suitable engine analyzer to the engine.
Allow the Engine to idle.
NOTE: If the Engine will not idle, maintain a constant RPM above idle.
NOTE: Set the scope to read display or parade pattern.
Follow the equipment manufacturer's procedure for pattern analysis.
Is the secondary ignition pattern OK?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 13
No®Repair the indicated component in the Secondary Ignition Sys-
tem.
Perform VERIFICATION TEST VER-5A2.
13 With the DRB, read the FREEZE FRAME DATA.
Use the freeze frame data and attempt to determine the cause of the misfire.
In the FREEZE FRAME, is the ENGINE RPM over 3000 and the operating temp
normal?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Lab scope cam and crank sensor, check valve timing, running
vacuum test.
Perform VERIFICATION TEST VER-5A2.
No®Go To 14
14The following additional items should be checked as possible mechanical
problems:
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions
ENGINE PCV SYSTEM - must flow freely
ENGINE DRIVE SPROCKETS - must be properly positioned
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A2.
No®Go To 15
15 The following are other possible causes for mis-fire:
Injector harness connectors, ignition coil circuit, spark plug, mechanical engine
problem, PCM power grounds, irregular cam and crank signal, injectors, restricted
exhaust, intake restriction, PCM, Evap System, EGR System, damaged trigger
wheel, and
accessory drive belts.
Do any of the above causes exist?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A2.
No®Test Complete.
107
DRIVEABILITY
P-0305 CYLINDER #5 MIS-FIRE ÐContinued
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Symptom:
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored and Set Condition:
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored: Under closed throttle decel; A/C off; engine coolant temp > 23 degrees
C (75 degrees F); longer than 50 seconds after engine start. The speed at which the
deceleration occurs must be sufficient for the given gear range, e.g., > 36 Km/h (36 mph)
in first gear or > 104 Km/h (> 65) in high gear.
Set Condition: When one of the CKP Sensor target windows 15 degrees C (60 degrees F)
has more than 2.86% variance from the reference window.
POSSIBLE CAUSES
CKP SENSOR CONNECTOR OBSERVABLE DEFECT
CKP SENSOR CONNECTOR OBSERVABLE DEFECT
CKP SENSOR DEFECTIVE
CKP SENSOR DEFECTIVE
CKP SENSOR NOT PROPERLY INSTALLED
CKP SENSOR NOT PROPERLY INSTALLED
NOTCHES IN CRANKSHAFT DEFECTIVE
SLOTS IN FLEXPLATE DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary.
Perform Verification Test VER-2A.
No®Go To 2
2 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Crankshaft Position Sensor for proper Torque and installation.
Is the Crankshaft Position Sensor properly installed?ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 3
No®Properly install CKP Sensor.
Perform Verification Test VER-2A.
198
DRIVEABILITY
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TEST ACTION APPLICABILITY
3 Ignition Off.
Remove the CKP Sensor.
Inspect the Slots in the Flexplate for debris, damage or excessive movement.
Is there any debris, damage or excessive movement?ENGINE - 3.0L V6
and/or ENGINE -
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-2A.
No®Go To 4
4 If there are no potential causes remaining, the CKP Sensor is assumed to be
defective.
View repair options.ENGINE - 3.0L V6
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Repair
Replace the CKP Sensor.
Perform Verification Test VER-2A.
5 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect all Terminals.
Is any Terminal damaged, pushed out or miswired?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Repair as necessary.
Perform Verification Test VER-2A.
No®Go To 6
6 Ignition Off.
Disconnect the Crankshaft Position Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect the Crankshaft Position Sensor for proper Torque and installation.
Is the Crankshaft Position Sensor properly installed?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Go To 7
No®Properly install CKP Sensor.
Perform Verification Test VER-2A.
7 Ignition Off.
Remove the Crankshaft Position Sensor.
Inspect the notches in the Crankshaft for debris, damage or excessive movement.
Is there any debris, damage or excessive movement?ENGINE -2.0L and
2.4L I-4 DOHC
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
8 If there are no potential causes remaining, the CKP Sensor is assumed to be
defective.
View repair options.ENGINE -2.0L and
2.4L I-4 DOHC
Repair
Replace the CKP Sensor.
Perform Verification Test VER-2A.
199
DRIVEABILITY
P-1398 MISFIRE ADAPTIVE NUMERATOR AT LIMIT ÐContinued
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Symptom:
* CHECKING THE ENGINE MECHANICAL SYSTEMS
POSSIBLE CAUSES
CHECKING ENGINE MECHANICAL SYSTEMS
TEST ACTION APPLICABILITY
1 At this point in the diagnostic test procedure, you have determined that all of the
engine electrical systems are operating as designed; therefore, they are not the cause
of the driveability problem.
The following additional items should be checked as possible mechanical causes of
the problem:
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
CAMSHAFT LOBES - check for abnormal wear
CRANK SENSOR PICK-UP - check crankshaft slots for debris/deterioration
ENGINE EXHAUST SYSTEM - must be free of any restrictions
ENGINE PCV SYSTEM - must flow freely
ENGINE DRIVE SPROCKETS - must be properly positioned
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Note: If you came to this test from the oxygen sensor, and the rich or lean
condition is not caused by one of the first items above, replace the power-
train control module and perform TEST VER-2A (Road Test Verification).
Always look for any Technical Service Bulletins that may relate to the problem.
Did you come from an Oxygen Sensor rich or lean condition test?All
Ye s®Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-2A.
No®Test Complete.
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DRIVEABILITY
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