CHRYSLER VOYAGER 2001 Service Manual

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
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DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Connect a jumper wire between APP Sensor Signal circuit and the 5-volt supply
circuit at the APP Sensor harness connector .
With the DRBIII, read the PEDAL OUTPUT VOLTS.
Does the DRBIII display between 4.0 and 5.5 volts?All
Ye s®Go To 5
No®Go To 12
5 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 ECM/PCM Relay connector.
Turn the ignition on.
Measure the voltage of the APP Sensor Ground circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the App Sensor Ground circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 6
6 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Sensor Ground circuit between the APP Sensor and the
ECM.
Is the resistance below 10.0 ohms?All
Ye s®Go To 7
No®Repair the APP Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7 Turn the ignition on.
With the DRB III, read the PEDAL OUTPUT VOLTS with the accelerator pedal in
the at rest position.
Does the DRB III display between 0.28 and 0.38 volt?All
Ye s®Go To 8
No®Replace the Accelerator Pedal Position Sensor in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
8 Turn the ignition on.
Fully depress the accelerator pedal.
With the DRBIII, read the PEDAL OUTPUT VOLTS.
Does the DRB III display between 4.1 and 4.6 volts?All
Ye s®Go To 9
No®Replace the Accelerator Pedal Position Sensor in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
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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.
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DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
13 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the APP Sensor Signal circuit.
Is the resistance below 1000 ohms?All
Ye s®Repair the APP Sensor Signal circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 14
14 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the APP Sensor Signal circuit and the Sensor
Ground circuit at of the APP Sensor harness connector.
Is the resistance below 1000 ohms?All
Ye s®Repair the APP Sensor Signal and Sensor Ground circuits for a
short together.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 15
15 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ECM/PCM Relay
connector.
Turn the ignition on.
Measure the voltage of the APP Sensor Signal circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the APP Sensor Signal circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
16 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the 5-volt Supply circuit.
Is the resistance below 10.0 ohms?All
Ye s®Go To 17
No®Repair the 5-volt Supply circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
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DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
17 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the 5-volt Supply circuit and the Sensor Ground
circuit at the APP Sensor harness connector.
Is the resistance above 1000 ohms for both of the measurements?All
Ye s®Go To 18
No®Repair the 5-volt Supply circuit for a short to the Sensor Ground
circuit.
Perform ROAD TEST VERIFICATION - VER-2.
18 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the 5-volt Supply circuit.
Is the resistance below 1000 ohms?All
Ye s®Repair the 5-volt Supply circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 19
19 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ECM/PCM Relay
connector.
Turn the ignition on.
Measure the voltage of the 5-volt Supply circuit in the ECM harness connector.
Is the voltage above 1.0 volt?All
Ye s®Repair the 5-volt Supply circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
20 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Low Idle Position Switch Sense circuit.
Is the resistance below 10.0 ohms?All
Ye s®Go To 21
No®Repair the Low Idle Position Switch Sense circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
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DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
21 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the Low Idle Position Switch Sense
circuit.
Is the resistance above 1000 ohms?All
Ye s®Go To 22
No®Repair the Low Idle Position Switch Sense circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
22 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the Low Idle Position Switch Sense circuit and the
Sensor Ground circuit at the APP Sensor harness connector.
Is the resistance above 1000 ohms?All
Ye s®Go To 23
No®Repair the Low Idle Position Switch Sense circuit and Sensor
Ground circuit for a short together.
Perform ROAD TEST VERIFICATION - VER-2.
23 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 ECM/PCM Relay connector.
Turn the ignition on.
Measure the voltage of the Low Idle Position Switch Sense circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the Low Idle Position Switch Sense circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 24
24 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 ECM/PCM Relay connector.
Turn the ignition on.
Measure the voltage of the Low Idle Position Switch Ground circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the Low Idle Position Switch Sense Ground circuit for a
short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 25
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DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
25 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Low Idle Switch Sensor Ground circuit between the
APP Sensor and the ECM.
Is the resistance below 10.0 ohms?All
Ye s®Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No®Repair the Low Idle Switch Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
178
DRIVEABILITY - DIESEL
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued

Symptom:
*CHECKING THE A/C CLUTCH OPERATION
POSSIBLE CAUSES
CHECK THE A/C CLUTCH OPERATION
FUSED B+ CIRCUIT OPEN
A/C CLUTCH RELAY
A/C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
A/C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO GROUND
A/C CLUTCH RELAY OUTPUT CIRCUIT OPEN
A/C CLUTCH GROUND CIRCUIT OPEN
A/C CLUTCH
TEST ACTION APPLICABILITY
1NOTE: Ensure that the refrigerant system is properly charged. Refer to the
appropriate Service Information.
Turn the ignition on.
With the DRBIIIt, actuate the A/C Clutch Relay.
Is the A/C Clutch actuating?All
Ye s®The A/C Clutch System is operating properly at this time.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 2
2NOTE: If the A/C Clutch fuse is open, refer to the system schematics for all
circuits that are powered by the A/C Clutch fuse to determine the cause of
the blown fuse.
Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the IPM.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Repair the Fused B+ circuit. Inspect fuse and replace as neces-
sary.
Perform ROAD TEST VERIFICATION - VER-2.
3 Turn the ignition off.
Install a substitute relay in place of the A/C Clutch Relay.
Turn the ignition on.
With the DRBIIIt, actuate the A/C Clutch Relay.
Does the A/C Clutch Relay cycle on and off?All
Ye s®Replace the A/C Clutch Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 4
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DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Disconnect the A/C Clutch harness connector.
Measure the voltage of the A/C Clutch Relay Output circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the A/C Clutch Relay Output circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 5
5 Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Disconnect the A/C Clutch harness connector.
Measure the resistance between ground and the A/C Clutch Relay Output circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 6
No®Repair the A/C Clutch Relay Output circuit for a short to ground.
Inspect fuse and replace as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Disconnect the A/C Clutch harness connector.
Measure the resistance of the A/C Clutch Relay Output circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the A/C Clutch Relay Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7 Turn the ignition off.
Disconnect the A/C Clutch harness connector.
Using a 12-volt test light connected to 12-volts, check the A/C Clutch Ground circuit.
Does the test light illuminate brightly?All
Ye s®Go To 8
No®Repair the A/C Clutch Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
8 If there are no possible causes remaining, view repair. All
Repair
Replace the A/C Clutch.
Perform ROAD TEST VERIFICATION - VER-2.
180
DRIVEABILITY - DIESEL
*CHECKING THE A/C CLUTCH OPERATION ÐContinued

Symptom:
*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR
CALIBRATION
POSSIBLE CAUSES
APP SENSOR
APP SENSOR - IDLE
APP SENSOR - WOT
TEST ACTION APPLICABILITY
1NOTE: Ensure the Accelerator pedal is free from any restriction or binding
before continuing.
Turn the ignition on.
While back probing, measure the voltage of the APP Sensor Signal circuit at the
ECM.
NOTE: The accelerator pedal must be released (Idle) for this step.
Is the voltage below 0.6 volt?All
Ye s®Go To 2
No®Replace the Accelerator Pedal Position Sensor in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
2 Turn the ignition on.
While back probing, measure the voltage of the APP Sensor Signal circuit at the
ECM.
Monitor the voltmeter while slowly pressing the accelerator pedal completely down.
Did the voltage increase smoothly with pedal travel?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.
3 Turn the ignition on.
While back probing, measure the voltage of the APP Sensor Signal circuit at the
ECM.
Press the accelerator pedal completely down.
Is the voltage above 3.7 volts with the accelerator pedal fully depressed?All
Ye s®Test Complete.
No®Replace the Accelerator Pedal Position Sensor in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
181
DRIVEABILITY - DIESEL