change time CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
8WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time.The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
161
DRIVEABILITY - DIESEL
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
4 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
5WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running and at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
163
DRIVEABILITY - DIESEL
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Install a substitute relay in place of the Fuel Heater Relay.
Disconnect the ECM harness connectors.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fuel Heater Relay Output
circuit.
Is the test light on?All
Ye s®Replace the initial Fuel Heater Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 5
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Crankcase Vent Heater harness connector.
Disconnect the Fuel Heater harness connector.
Remove the Fuel Heater Relay from the IPM.
Measure the resistance between ground and the Battery(+) Sense circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 6
No®Repair the Battery(+) Sense circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
7WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running and at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
165
DRIVEABILITY - DIESEL
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO LOW ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the IPM.
Turn the ignition on.
Measure the voltage on ECM harness connector C1 cavities 4 and 5.
Is the voltage below 2.0 volts on both circuits?All
Ye s®Go To 5
No®Repair the ECM/PCM Relay Output circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the IPM.
Measure the resistance between ground and the ECM/PCM Relay Control circuit.
Is the resistance above 100k ohms?All
Ye s®Replace the ECM/PCM Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No®Repair the ECM/PCM Relay Control circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
6WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
167
DRIVEABILITY - DIESEL
P1605-IGNITION SWITCH PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
2 Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Turn the ignition on and off several times pausing 10 seconds between each key cycle.
With the DRBIIIt, read the ECM DTCs.
Are any P1685 DTCs present?All
Ye s®Go To 3
No®Go To 4
3 Replace and program the SKIM in accordance with the Service Information.
Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Turn the ignition on and off several times pausing for 10 seconds between key cycles.
With the DRBIIIt, read ECM DTCs.
Are there any P1685 DTC's present?All
Ye s®Replace and program the ECM in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
4WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
169
DRIVEABILITY - DIESEL
P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED ÐContinued

POSSIBLE CAUSES
APP SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE
LOW IDLE POSITION SWITCH SENSE GROUND CIRCUIT SHORTED TO VOLTAGE
VERIFY CORRECT SWITCHING
ECM - APP SENSOR SIGNAL CIRCUIT
TEST ACTION APPLICABILITY
1NOTE: The brake switch must be operational for the result of this test to be
valid.
Turn the ignition off.
Disconnect the APP Sensor harness connector.
Connect one end of a jumper wire to the Low Idle Position Sense circuit at the APP
Sensor harness connector.
Turn the ignition on.
With the DRB III, monitor the Low Idle Position Switch input while tapping the other
end of the jumper wire to the Sensor Ground circuit at the APP Sensor harness
connector.
Does the DRB III change between IDLE and ABOVE IDLE when tapping the jumper
wire?All
Ye s®Go To 2
No®Go To 20
2 Turn the ignition on.
With the DRB III observe the Low Idle Position Switch input.
Press and release the accelerator pedal several times while observing the DRB III
display.
NOTE: The Low Idle Position Switch input should change from IDLE to
ABOVE IDLE when pressing and releasing the accelerator pedal.
Did Low Idle Position Switch input change between IDLE and ABOVE IDLE?All
Ye s®Go To 3
No®Replace the Accelerator Pedal Position Sensor in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
3NOTE: If DTC P0641 or P0651 is present with this DTC, diagnose DTCs
P0641 and P0651 before diagnosing this DTC.
Turn the ignition off.
Disconnect the APP Sensor harness connector.
Turn the ignition on.
Measure the voltage of the 5-volt Supply circuit in APP Sensor harness connector.
Is the voltage between 4.7 and 5.3 volts?All
Ye s®Go To 4
No®Go To 16
172
DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
9 Turn the ignition on.
With the DRB III, read the PEDAL OUTPUT VOLTS.
With the accelerator pedal in the idle position, slowly depress the accelerator pedal
until the pedal is fully depressed.
NOTE: The PEDAL OUTPUT VOLTS should increase smoothly as the pedal
is depressed.
Does the voltage increase smoothly with the accelerator pedal travel?All
Ye s®Go To 10
No®Replace the Accelerator Pedal Position Sensor in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
10 Turn the ignition on.
With the DRB III, select Engine and with the custom display feature select Low Idle
Switch input and the Accel Pedal %.
Slowly depress and release the accelerator pedal several times while monitoring the
DRB III display.
NOTE: The Low Idle Switch state should change between 5% and 10% of
Accelerator Pedal position.
Did the Low Idle Switch state change between 5% and 10% of Accelerator Pedal
position?All
Ye s®Go To 11
No®Replace the Accelerator Pedal Position Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
11WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running and at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
12 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the APP Sensor Signal circuit.
Is the resistance below 10.0 ohms?All
Ye s®Go To 13
No®Repair the APP Sensor Signal circuit for an open
Perform ROAD TEST VERIFICATION - VER-2.
174
DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition on.
With the DRBIIItin Sensors, read the Vehicle Speed Sensor signal.
Have an assistant drive the vehicle while you are observing the Vehicle Speed Signal
on the DRB.
While observing vehicle speed signal note any rapid changes (signal drop-outs) in the
reading that do not correspond with actual vehicle speed.
Is the DRB displaying an accurate Vehicle Speed Signal?All
Ye s®Go To 5
No®Refer to symptom list for problems related to the Vehicle Speed
Sensor.
Perform SPEED CONTROL VERIFICATION - VER-4.
5 Turn the ignition on.
With the DRBIIItin Inputs/Outputs, read the Primary and Secondary switch states
while pressing and releasing the Brake Pedal several times.
Did the DRB indicate the correct brake pedal state when pressing and releasing the
Brake Pedal?All
Ye s®Go To 6
No®Refer to symptom list for problems related to Brake Switch input.
Perform SPEED CONTROL VERIFICATION - VER-4.
6 Turn the ignition on.
With the DRBIIItin Inputs/Outputs, read the Clutch switch states while pressing
and releasing the Clutch Pedal several times.
Did the DRB indicate the correct clutch pedal state when pressing and releasing the
Clutch Pedal?All
Ye s®Go To 7
No®Go To 8
7WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary.
Perform SPEED CONTROL VERIFICATION - VER-4.
No®Replace and program the ECM in accordance with the Service
Information.
Perform SPEED CONTROL VERIFICATION - VER-4.
202
DRIVEABILITY - DIESEL
*CHECKING THE SPEED CONTROL OPERATION ÐContinued

Verification Tests
CHARGING VERIFICATION - VER-3 APPLICABILITY
1. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
2. If the PCM has been replaced, perform step 3. Otherwise, continue with step 4.
3. If the vehicle is equipped with a factory theft alarm, start the engine at least 20 times in
order to be able to activate the alarm system when desired.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Start the engine.
6. Raise the engine speed to 2000 RPM for at least 30 seconds.
7. Allow the engine to idle.
8. Turn the ignition off for 20 seconds.
9. Turn the ignition on.
10. With the DRB, read ECM and PCM DTCs.
11. If this DTC has reset, or another DTC has set, look for any Technical Service Bulletins
(TSBs) that may relate to this condition. Return to the Symptom List if necessary.
12. If the charging system is functioning correctly and there are no DTCs, the repair is now
complete.
Are any DTCs or symptoms remaining?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
NO START VERIFICATION - VER-1 APPLICABILITY
1. NOTE: IMPORTANT! If the Engine Control Module, Sentry Key Immobilizer
Module or Powertrain Control Module have been replaced, ensure the programming
procedures for these modules have been performed in accordance with the Service
Information.
2. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Turn the ignition off for at least 10 seconds.
6. Attempt to start the engine.
7. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may
relate to this condition. Return to the Symptom List if necessary.
8. If the engine starts and continues to run, the repair is now complete.
Are any DTCs or symptoms remaining?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
223
VERIFICATION TESTS

CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 5).
This symbol on the front of an oil container means
that the oil has been certified by the American Petro-
leum Institute (API) to meet all the lubrication
requirements specified by DaimlerChrysler.
FLEXIBLE FUEL ENGINE OIL - 3.3L
Engine Oil Selection for Operating on E-85 Fuel
If vehicle operates on E-85 fuel either full or part-
time, use only MopartFlexible Fuel 5W-30 engine oil
or an equivalent that meets DaimlerChrysler Stan-
dard MS-9214. Equivalent commercial Flexible Fuel
engine oils may be labeled as Multi-Fuel, Variable
Fuel, Flexible Fuel, etc. These engine oils may be
satisfactory if they meet the DaimlerChrysler Stan-
dard.
SAE 5W-30 engine oil is preferred for use in Flex-
ible Fuel engines.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for this transaxle.
NOTE: For fluid level checking procedures, (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/FLUID - STANDARD PROCEDURE) (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE/
FLUID - STANDARD PROCEDURE)NOTE: The 41TE transaxle has a common transmis-
sion and differential sump. Filling the transaxle
accommodates the differential as well.
TRANSMISSION FLUID
MopartATF+4 (Automatic Transmission Fluid-
Type 9602) is required in this transaxle. Substitute
fluids can induce torque converter clutch shudder.
MopartATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown.This is normal.A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Fig. 5 Engine Oil Container Standard Notations
0 - 4 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)