fan CHRYSLER VOYAGER 2001 Service Manual

put component, it can verify that the command was
carried out by monitoring specific input signals for
expected changes. For example, when the PCM com-
mands the Idle Air Control (IAC) Motor to a specific
position under certain operating conditions, it expects
to see a specific (target) idle speed (RPM). If it does
not, it stores a DTC.
PCM outputs monitored for functionality include:
²Fuel Injectors
²Ignition Coils
²Torque Converter Clutch Solenoid
²Idle Air Control
²Purge Solenoid
²EGR Solenoid
²LDP Solenoid
²Radiator Fan Control
²Trans Controls
OXYGEN SENSOR (O2S) MONITOR
DESCRIPTIONÐEffective control of exhaust
emissions is achieved by an oxygen feedback system.
The most important element of the feedback system
is the O2S. The O2S is located in the exhaust path.
Once it reaches operating temperature 300É to 350ÉC
(572É to 662ÉF), the sensor generates a voltage that
is inversely proportional to the amount of oxygen in
the exhaust. When there is a large amount of oxygen
in the exhaust caused by a lean condition, the sensor
produces a low voltage, below 450 mV. When the oxy-
gen content is lower, caused by a rich condition, the
sensor produces a higher voltage, above 450mV.
The information obtained by the sensor is used to
calculate the fuel injector pulse width. The PCM is
programmed to maintain the optimum air/fuel ratio.
At this mixture ratio, the catalyst works best to
remove hydrocarbons (HC), carbon monoxide (CO)
and nitrous oxide (NOx) from the exhaust.
The O2S is also the main sensing element for the
EGR, Catalyst and Fuel Monitors.
The O2S may fail in any or all of the following
manners:
²Slow response rate (Big Slope)
²Reduced output voltage (Half Cycle)
²Heater Performance
Slow Response Rate (Big Slope)ÐResponse rate
is the time required for the sensor to switch from
lean to rich signal output once it is exposed to a
richer than optimum A/F mixture or vice versa. As
the PCM adjusts the air/fuel ratio, the sensor must
be able to rapidly detect the change. As the sensor
ages, it could take longer to detect the changes in the
oxygen content of the exhaust gas. The rate of
change that an oxygen sensor experiences is called
'Big Slope'. The PCM checks the oxygen sensor volt-
age in increments of a few milliseconds.Reduced Output Voltage (Half Cycle)ÐThe
output voltage of the O2S ranges from 0 to 1 volt. A
good sensor can easily generate any output voltage in
this range as it is exposed to different concentrations
of oxygen. To detect a shift in the A/F mixture (lean
or rich), the output voltage has to change beyond a
threshold value. A malfunctioning sensor could have
difficulty changing beyond the threshold value. Each
time the voltage signal surpasses the threshold, a
counter is incremented by one. This is called the Half
Cycle Counter.
Heater PerformanceÐThe heater is tested by a
separate monitor. Refer to the Oxygen Sensor Heater
Monitor.
OPERATIONÐAs the Oxygen Sensor signal
switches, the PCM monitors the half cycle and big
slope signals from the oxygen sensor. If during the
test neither counter reaches a predetermined value, a
malfunction is entered and a Freeze Frame is stored.
Only one counter reaching its predetermined value is
needed for the monitor to pass.
The Oxygen Sensor Monitor is a two trip monitor
that is tested only once per trip. When the Oxygen
Sensor fails the test in two consecutive trips, the
MIL is illuminated and a DTC is set. The MIL is
extinguished when the Oxygen Sensor monitor
passes in three consecutive trips. The DTC is erased
from memory after 40 consecutive warm-up cycles
without test failure.
Enabling ConditionsÐThe following conditions
must typically be met for the PCM to run the oxygen
sensor monitor:
²Battery voltage
²Engine temperature
²Engine run time
²Engine run time at a predetermined speed
²Engine run time at a predetermined speed and
throttle opening
²Transmission in gear (automatic only)
²Fuel system in Closed Loop
²Long Term Adaptive (within parameters)
²Power Steering Switch in low PSI (no load)
²Engine at idle
²Fuel level above 15%
²Ambient air temperature
²Barometric pressure
²Engine RPM within acceptable range of desired
idle
²Closed throttle speed
Pending ConditionsÐThe Task Manager typi-
cally does not run the Oxygen Sensor Monitor if over-
lapping monitors are running or the MIL is
illuminated for any of the following:
²Misfire Monitor
²Front Oxygen Sensor and Heater Monitor
²MAP Sensor
25 - 2 EMISSIONS CONTROLRS
EMISSIONS CONTROL (Continued)

Generic Scan Tool Code DRB IIITScan Tool Display
P0403 EGR Solenoid Circuit Open Circuit
EGR Solenoid Circuit Short Circuit
P0480 Fan 1 Control Circuit Open Circuit
Fan 1 Control Circuit Short Circuit
P0481 Fan 2 Control Circuit Open Circuit
Fan 2 Control Circuit Short Circuit
P0500 Vehicle Speed Sensor Frequency Too High
Vehicle Speed Sensor Frequency High Level Duration
Vehicle Speed Sensor Plausibility
Vehicle Speed Sensor Signal Voltage Too High
P0514 Battery Temperature Sensor Circuit Signal Voltage Too High
P0520 Oil Pressure Sensor Circuit MALF Signal Voltage Too High
Oil Pressure Sensor Circuit MALF Signal Voltage Too Low
Oil Pressure Sensor Circuit MALF Signal Voltage Too Low or High
P0530 A/C Pressure Sensor Circuit Plausibility
A/C Pressure Sensor Circuit Signal Voltage Too High
A/C Pressure Sensor Circuit Signal Voltage Too Low
A/C Pressure Sensor Circuit Supply Voltage Too High Or Low
P0560 System Voltage Too High
System Voltage Too Low
P0579 Speed Control Switch Signal Circuit Voltage Too High
Speed Control Switch Signal Circuit Voltage Too Low
P0606 ECM Error Gate Array - Communication
ECM Error Gate Array - Communication Not Verified
ECM Error Gate Array - Quantity Stop
ECM Error Gate Array - Has Occurred
ECM Error Redundant Overrun Monitoring
P0615 Starter Relay Circuit Open Circuit
Starter Relay Circuit Short Circuit
P0620 Generator Field Control MALF Open Circuit
Generator Field Control MALF Short Circuit
P0641 Sensor Reference Voltage A CKT Voltage Too High
Sensor Reference Voltage A CKT Voltage Too Low
P0645 A/C Clutch Relay Circuit Open Circuit
A/C Clutch Relay Circuit Short Circuit
P0651 Sensor Reference Voltage B CKT Voltage Too Low
Sensor Reference Voltage B CKT Voltage Too High
25a - 8 ON-BOARD DIAGNOSTICSRG
ON-BOARD DIAGNOSTICS (Continued)

TABLE OF CONTENTS - Continued
P0325-KNOCK SENSOR #1 CIRCUIT......................................113
P0340-NO CAM SIGNAL AT PCM.........................................116
P0351-IGNITION COIL #1 PRIMARY CIRCUIT..............................121
P0352-IGNITION COIL #2 PRIMARY CIRCUIT..............................121
P0353-IGNITION COIL #3 PRIMARY CIRCUIT..............................121
P0401 - EGR SYSTEM FAILURE.........................................124
P0403 - EGR SOLENOID CIRCUIT........................................128
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY...........................131
P0441-EVAP PURGE FLOW MONITOR....................................133
P0442-EVAP LEAK MONITOR MEDIUM (.040) LEAK DETECTED...............136
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED.....................136
P0456 - EVAP LEAK MONITOR SMALL LEAK DETECTED....................136
P0443-EVAP PURGE SOLENOID CIRCUIT.................................139
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES........................142
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW.......................145
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH......................145
P0500-NO VEHICLE SPEED SIGNAL (3SP AUTO AND MANUAL
TRANSMISSIONS).....................................................147
P0500-NO VEHICLE SPEED SIGNAL (4SP AUTO TRANS)....................150
P0505-IDLE AIR CONTROL MOTOR CIRCUITS.............................153
P0508 - IAC MOTOR SENSE CIRCUIT LOW................................156
P0509 - IAC MOTOR SENSE CIRCUIT HIGH...............................159
P0700-EATX CONTROLLER DTC PRESENT................................161
P0703-BRAKE SWITCH SENSE CIRCUIT..................................162
P0740-TORQ CONV CLU, NO RPM DROP AT LOCKUP (3SP AUTO TRANS).....165
P0743-TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIRCUITS
(3SP AUTO TRANS)....................................................168
P0833-CLUTCH RELEASED SWITCH CIRCUIT.............................171
P1192-INLET AIR TEMP SENSOR VOLTAGE LOW...........................174
P1193-INLET AIR TEMP SENSOR VOLTAGE HIGH..........................176
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR................178
P1281-ENGINE IS COLD TOO LONG......................................180
P1282-FUEL PUMP RELAY CONTROL CIRCUIT.............................181
P1294-TARGET IDLE NOT REACHED (2.4L)................................184
P1294-TARGET IDLE NOT REACHED (3.3L/3.8L)............................187
P1297-NO CHANGE IN MAP FROM START TO RUN.........................189
P1299-VACUUM LEAK FOUND (IAC FULLY SEATED)........................193
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT.......................195
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM.........................198
P1391-INTERMITTENT LOSS OF CMP OR CKP.............................201
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT.........................205
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND......................207
P1491-RAD FAN CONTROL RELAY CIRCUIT...............................210
P1494-LEAK DETECT PUMP SW OR MECHANICAL FAULT...................214
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT.......................216
P1496-5 VOLT SUPPLY, OUTPUT TOO LOW...............................218
P1602-PCM NOT PROGRAMMED........................................221
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (3SP AUTO TRANS)........222
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (4SP AUTO TRNAS)........224
*CHECKING ECT SENSOR..............................................226
*CHECKING FUEL DELIVERY............................................227
*CHECKING IAC MOTOR (2.4L)..........................................231
*CHECKING IAT SENSOR...............................................232
iii

TABLE OF CONTENTS - Continued
*CHECKING MAP SENSOR..............................................233
*CHECKING PCM POWER AND GROUND CIRCUITS........................234
*CHECKING RADIATOR FAN RELAY OUTPUT..............................235
*CHECKING THE A/C RELAY OUTPUT....................................236
*CHECKING TP SENSOR...............................................238
HEATING & A/C
P0645-A/C CLUTCH RELAY CKT.........................................239
P1598-A/C PRESSURE SENSOR VOLTS TOO HIGH.........................242
P1599-A/C PRESSURE SENSOR VOLTS TOO LOW.........................245
SPEED CONTROL
P1595-SPEED CONTROL SOLENOID CIRCUITS............................248
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT...................248
STARTING
*ENGINE CRANKS DOES NOT START....................................253
*NO CRANK CONDITION................................................258
*NO RESPONSE FROM PCM WITH A NO START CONDITION................261
*START AND STALL CONDITION.........................................262
VEHICLE THEFT/SECURITY
ANTENNA FAILURE....................................................266
COP FAILURE.........................................................266
EEPROM FAILURE.....................................................266
INTERNAL FAULT......................................................266
RAM FAILURE.........................................................266
SERIAL LINK INTERNAL FAULT..........................................266
STACK OVERFLOW FAILURE............................................266
PCM STATUS FAILURE.................................................268
SERIAL LINK EXTERNAL FAULT.........................................268
ROLLING CODE FAILURE...............................................270
TRANSPONDER COMMUNICATION FAILURE..............................272
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE.............272
TRANSPONDER ID MISMATCH..........................................272
TRANSPONDER RESPONSE MISMATCH..................................272
VERIFICATION TESTS
VERIFICATION TESTS..................................................275
8.0 COMPONENT LOCATIONS..............................................283
8.1CONTROL MODULES AND FUSE & RELAY CENTER...................283
8.2CONTROLS AND SOLENOID.......................................283
8.3DATA LINK CONNECTOR..........................................285
8.4SENSORS.......................................................286
8.5FUEL SYSTEM...................................................288
8.6SWITCHES......................................................289
9.0 CONNECTOR PINOUTS................................................291
A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY............................291
A/C PRESSURE TRANSDUCER - GRAY 4 WAY.............................291
AIR TEMPERATRUE SENSOR - BLACK 2 WAY.............................291
iv

TEST ACTION APPLICABILITY
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 DRB Freeze Frame information. 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 POWERTRAIN VERIFICATION TEST VER - 3.
No®Test Complete.
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Driver circuit from the PCM harness
connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Generator Field Driver circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 6
6 Turn the ignition off.
Disconnect the Generator Field harness connector.
Measure resistance of the Generator Field Driver terminal to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair or replace the shorted Generator as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 7
7 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
19
CHARGING
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH ÐContinued

TEST ACTION APPLICABILITY
2WARNING: 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.
Turn the ignition on.
NOTE: Ensure all wires are clear of the engine's moving parts.
Measure the voltage between the Generator B+ Terminal and the Battery+ Post.
Start the engine.
Is the voltage above 0.4 volt?All
Ye s®Repair the B+ circuit for high resistance between the Generator
and Battery.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 3
3WARNING: 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.
Start the engine.
Warm the engine to operating temperature.
NOTE: Ensure all wires are clear of the engine's moving parts.
Measure the voltage between the Generator case and Battery ground post.
Is the voltage above 0.1 volt?All
Ye s®Repair Generator Ground for high resistance, Generator Case to
Battery ground side.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 4
4 Start the engine.
WARNING: 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.
Turn on all accessories, manually set engine speed to 1600 RPM.
With DRBIIIt, read Target Charging and Charging voltage.
Compare the two readings.
Is there more than a 1.0 volt difference?All
Ye s®Go To 5
No®Go To 8
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Driver circuit from the PCM harness
connector to Generator harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Generator Field Driver circuit an open.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
21
CHARGING
P1682-CHARGING SYSTEM VOLTAGE TOO LOW ÐContinued

TEST ACTION APPLICABILITY
6 Disconnect the Generator Field harness connector.
Turn the ignition on.
With the DRBIIItactuate the Generator Field Driver.
Using a 12-volt test light connected to ground, probe the ASD Relay Output circuit.
Does the test light illuminate brightly?All
Ye s®Go To 7
No®Repair the ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
7 If there is no possible causes remaining, view repair. All
Ye s®Repair or replace the Generator as necessary..
Perform POWERTRAIN VERIFICATION TEST VER - 3.
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 DRB Freeze Frame information. 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 POWERTRAIN VERIFICATION TEST VER - 3.
No®Test Complete.
22
CHARGING
P1682-CHARGING SYSTEM VOLTAGE TOO LOW ÐContinued

TEST ACTION APPLICABILITY
3WARNING: 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 DRB Freeze Frame information. 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 POWERTRAIN VERIFICATION TEST VER-1.
No®Test Complete.
29
COMMUNICATION
P1695-NO CCD/J1850 MESSAGE FROM BODY CONTROL MODULE Ð
Continued

TEST ACTION APPLICABILITY
3WARNING: 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 DRB Freeze Frame information. 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 POWERTRAIN VERIFICATION TEST VER-1.
No®Test Complete.
33
COMMUNICATION
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE ÐContinued

TEST ACTION APPLICABILITY
4NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Backprobe between the Sensor ground circuit at the IAT Sensor harness connector
and PCM harness connector.
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 volt?All
Ye s®Go To 5
No®Repair the high resistance in the Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Backprobe between the IAT Sensor Signal circuit at the IAT Sensor harness
connector and PCM harness connector.
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 volt?All
Ye s®Go To 6
No®Repair the high resistance in the IAT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
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 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 DRB Freeze Frame information to identify under what conditions the
DTC 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 POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
44
DRIVEABILITY - GAS
P0071 - AMBIENT TEMP SENSOR PERFORMANCE ÐContinued