engine coolant CHRYSLER VOYAGER 2001 Service Manual

Symptom:
P1494-LEAK DETECT PUMP SW OR MECHANICAL FAULT
When Monitored and Set Condition:
P1494-LEAK DETECT PUMP SW OR MECHANICAL FAULT
When Monitored: Immediately after a cold start, with battery/ambient temperature
between 4ÉC (40ÉF) and 32ÉC (90ÉF) and coolant temperature within -12ÉC (10ÉF) of
battery/ambient.
Set Condition: The state of the switch does not change when the solenoid is energized.
POSSIBLE CAUSES
LDP VACUUM SUPPLY
WIRING HARNESS INTERMITTENT
LEAK DETECTION PUMP
LDP SWITCH SENSE CIRCUIT SHORTED TO GROUND
LDP SWITCH SENSE CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the Good Trip displayed and equal to zero?All
Ye s®Go To 2
No®Go To 7
2 Turn the ignition off.
Disconnect the vacuum supply hose at the Leak Detection Pump.
Connect a vacuum gauge to the disconnected vacuum supply hose at the Leak
Detection Pump.
Start the engine and read the vacuum gauge.
Does the vacuum gauge read at least 13 in/Hg?All
Ye s®Go To 3
No®Repair leak or obstruction in vacuum hose as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
214
DRIVEABILITY - GAS

Symptom:
*CHECKING ECT SENSOR
POSSIBLE CAUSES
ECT SENSOR OPERATION
ECT SENSOR
TEST ACTION APPLICABILITY
1NOTE: The engine coolant temperature must be below 62ÉC (150ÉF).
Turn the ignition on.
With the DRBIIIt, monitor the ECT value.
Start the engine.
Does the ECT reach 82ÉC (180ÉF) and was it a smooth transition?All
Ye s®Engine Coolant Temperature sensor is operating normally.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Replace the Engine Coolant Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
226
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
8 The following items need to be checked as a possible cause for a no start condition.
Refer to any Technical Service Bulletins that may apply to the symptom.
The spark plugs must be free from fuel, oil, coolant and/or any foreign material or
deposits.
The fuel must be free from contamination.
The exhaust may be free from restrictions.
The engine compression must be within specifications.
The engine valve timing must be within specifications.
The engine must be free from vacuum leaks.
Were any of the above conditions found?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Test Complete.
9 Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Using a 12 volt test light connected to ground, probe the Fuel Pump Relay Output
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 10
No®Go To 12
Caution: Stop All Actuations.
10 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Note: Check connectors - It is critical that the connector is free from any
signs of corrosion or deformities - Clean/repair as necessary.
Using a test light connected to battery voltage, probe the Fuel Pump ground circuit
at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 11
No®Repair the open/high resistance in the fuel pump ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
11 If there are no possible causes remaining, view repair. All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
12 Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
With a 12 volt test light connected to ground, probe the Fuel Pump Relay Fused B+
circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 13
No®Check for an open Fuel Pump fuse, repair cause of open. If OK,
replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
256
STARTING
*ENGINE CRANKS DOES NOT START ÐContinued

TEST ACTION APPLICABILITY
9Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soaked).
NOTE: If the vehicle was allow to sit over night with no engine start, coolant
temperature should be near ambient temperatures.
Turn the ignition on.
With the DRBIIIt, read the Engine Coolant Temperature value.
Note: If engine coolant temperature is above 82É C (180É F), allow the engine
to cool until 65É C (150É F) is reached.
Start the engine.
During engine warm-up, monitor the Engine Coolant Temperature value. The
temperature value change should be a smooth transition from start up to normal
operating temp 82É C (180É F). The value should reach at least 82É C (180É F).
Did the Engine Temperature value increase smoothly and did it reach at least 82É C
(180É F)?All
Ye s®Go To 10
No®Replace the Engine Coolant Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER-1.
10 The following additional items should be checked as a possible cause for a start and
stall condition.
Refer to any Technical Service Bulletins (TSB's) that may apply to the symptom.
Fuel must be free of contamination.
The exhaust system must be free of any restrictions.
The engine compression must be within specifications.
The engine valve timing must be within specifications.
The engine must be free from vacuum leaks.
The throttle body must be free of carbon buildup and dirt.
Do any of the above conditions exist?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Test Complete.
265
STARTING
*START AND STALL CONDITION ÐContinued

EGR SOLENOID - GRAY 2 WAYCAV CIRCUIT FUNCTION
1 K35 18DB/VT EGR SOLENOID CONTROL
2 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
ENGINE COOLANT TEMPERATURE SENSOR - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL PRESSURE SWITCH - LT. GREEN 2 WAYCAV CIRCUIT FUNCTION
1 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
2- -
EVAP/PURGE SOLENOID - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL
2 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE
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CONNECTOR PINOUTS

POWERTRAIN CONTROL MODULE C1 - GRAY/BLACK 40 WAYCAV CIRCUIT FUNCTION
1- -
2 K18 16DB/OR (3.3L/3.8L) IGNITION COIL NO. 3 DRIVER
3 K17 16DB/TN IGNITION COIL NO. 2 DRIVER
4- -
5 V32 18VT/YL SPEED CONTROL ON/OFF SWITCH SENSE
6 K342 16BR/WT AUTOMATIC SHUTDOWN RELAY OUTPUT
7 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER
8 K20 18BR/GY GENERATOR FIELD DRIVER (+)
9- -
10 Z130 18BK/BR GROUND
11 K19 16DB/DG IGNITION COIL NO. 1 DRIVER
12 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
13 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER
14 K58 16BR/VT (3.3L/3.8L) FUEL INJECTOR NO. 6 DRIVER
15 K38 16BR/OR (3.3L/3.8L) FUEL INJECTOR NO. 5 DRIVER
16 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER
17 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER
18 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL
19 - -
20 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
21 - -
22 - -
23 - -
24 - -
25 K42 18DB/YL KNOCK SENSOR SIGNAL
26 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
27 K902 18BR/DG OXYGEN SENSOR GROUND
28 - -
29 - -
30 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL
31 T752 18DG/OR DOUBLE START OVERRIDE
32 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL
34 - -
35 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
36 K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
37 K21 18DB/LG INTAKE AIR TEMPERATURE SIGNAL
38 - -
39 - -
40 K35 18DB/VT EGR SOLENOID CONTROL
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CONNECTOR PINOUTS

3.2.2 TRANSMISSION OPERATION AND
SHIFT SCHEDULING AT VARIOUS
OIL TEMPERATURES.
The transmission covered in this manual has
unique shift schedules depending on the tempera-
ture of the transmission oil. The shift schedule is
modified to extend the life of the transmission while
operating under extreme conditions.
The oil temperature is measured with a Temper-
ature Sensor on the 41TE/AE transmission. The
Temperature Sensor is an integral component of the
Transmission Range Sensor (TRS). If the Tempera-
ture Sensor is faulty, (DTC P1799(74)) the trans-
mission will default to a calculated oil temperature.
Oil temperature will then be calculated through a
complex heat transfer equation which uses engine
coolant temperature, battery/ambient temperature,
and engine off time from the Body Control Module
(BCM). These inputs are received from the PCI bus
periodically and used to initialize the oil tempera-
ture at start up. Once the engine is started, the
TCM updates the transmission oil temperature
based on torque converter slip speed, vehicle speed,
gear, and engine coolant temperature to determine
an estimated oil temperature during vehicle opera-
tion. Vehicles using a calculated oil temperature
track oil temperature reasonably accurate during
normal operation. However, if a transmission is
overfilled, a transmission oil cooler becomes re-
stricted, or if a customer drives aggressively in low
gear, the calculated oil temperature will be inaccu-
rate. Consequently the shift schedule selected may
be inappropriate for the current conditions. The key
highlights of the various shift schedules are as
follows:
Extreme Cold:Oil temperature at start up below
-26.6C (-16ÉF)
> Goes to a Cold schedule above -24C (-12ÉF) oil
temperature
> Park, Reverse, Neutral and 2nd gear only (pre-
vents shifting which may fail a clutch with fre-
quent shifts)
Cold:Oil temperature at start up above -24C
(-12ÉF) and below 2.2C (36ÉF)
> Goes to a Warm schedule above 4.4C (40ÉF) oil
temperature
> Delayed 2-3 upshift approximately 35-50 Km/h
(22-31 MPH)
> Delayed 3-4 upshift 72-85 Km/h (45-53 MPH)
> Early 4-3 coastdown shift approximately 48
Km/h (30 MPH)
> Early 3-2 coastdown shift approximately 27
Km/h (17 MPH)> High speed 4-2, 3-2, 2-1 kickdown shifts are
prevented
> No EMCC
Warm:Oil temperature at start up above 2.2C
(36ÉF) and below 27C (80ÉF)
> Goes to a Hot schedule above 27C (80ÉF) oil
temperature
> Normal operation (upshifts, kickdowns, and
coastdowns)
> No EMCC
Hot:Oil temperature at start up above 27C (80ÉF)
> Goes to a Overheat schedule above 115C (240ÉF)
oil temperature
> Normal operation (upshifts, kickdowns, and
coastdowns)
> Full EMCC, No PEMCC except to engage
FEMCC
(Except at closed throttle at speeds above 113-133
Km/h (70 - 83 MPH)
Overheat:Oil temperature above 115C (240ÉF) or
engine coolant temperature above 118C (244ÉF)
> Goes to a Hot below 110C (230ÉF) oil temperature
or a Super Overheat above 115C (240ÉF) oil
temperature
> Delayed 2-3 upshift 40-51 Km/h (25-32 MPH)
> Delayed 3-4 upshift 66-77 Km/h (41-48 MPH)
> 3rd gear FEMCC from 48-77 Km/h (30-48 MPH)
> 3rd gear PEMCC from 43-50 Km/h (27-31 MPH)
Super Overheat:Oil temperature above 127C
(260ÉF)
> Goes back to a Overheat below 115C (240ÉF) oil
temperature
> All a Overheat shift schedules features apply
> 2nd gear PEMCC above 35 Km/h (22 MPH)
> Above 35 Km/h (22 MPH) the torque converter
will not unlock unless the throttle is closed (i.e. at
80 Km/h (50 MPH) a 4th FEMCC to 3rd FEMCC
shift will be made during a part throttle kick-
down or a 4th FEMCC to 2nd PEMCC shift will
be made at wide open throttle) or if a wide open
throttle 2nd PEMCC to 1 kickdown is made.
Causes for operation in the wrong tempera-
ture shift schedule:
Extreme Cold or Cold shift schedule at start up:
> Temperature Sensor circuit.
Overheat or Super Overheat shift schedule after
extended operation:
> Operation in city traffic or stop and go traffic
> Engine idle speed too high
> Aggressive driving in low gear
2
GENERAL INFORMATION

> Trailer towing in OD gear position (use 3 position
(or A/S 3rd) if frequent shifting occurs)
> Cooling system failure causing engine to operate
over 110C (230ÉF)
> Engine coolant temperature stays low too long -
If engine coolant temperature drops below 65C
(150ÉF), the transmission will disengage EMCC.
Extended operation with the EMCC disengaged
will cause the transmission to overheat.
> A brake switch issue will cause the EMCC to
disengage. Extended operation with the EMCC
disengaged will cause the transmission to over-
heat.
> Transmission fluid overfilled
> Transmission cooler or cooler lines restricted
> Transmission Temperature Sensor circuit
3.3 DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC's) are codes stored
by the Transmission Control Module (TCM) that
help us diagnose Transmission problems. They are
viewed using the DRBIIItscan tool.
Always begin by performing a visual inspection of
the wiring, connectors, cooler lines and the trans-
mission. Any obvious wiring problems or leaks
should be repaired prior to performing any diagnos-
tic test procedures. Some engine driveability prob-
lems can be misinterpreted as a transmission prob-
lem. Ensure that the engine is running properly
and that no PCM DTC's are present that could
cause a transmission complaint.
If there is a communication bus problem, trouble
codes will not be accessible until the problem is
fixed. The DRBIIItwill display an appropriate
message. The following is a possible list of causes
for a bus problem:
± open or short to ground/battery in PCI bus
circuit (pin 43).
± internal failure of any module or component on
the bus
Each diagnostic trouble code is diagnosed by
following a specific testing sequence. The diagnostic
test procedures contain step-by-step instructions
for determining the cause of a transmission diag-
nostic trouble code. Possible sources of the code are
checked and eliminated one by one. It is not neces-
sary to perform all of the tests in this book to
diagnose an individual code. These tests are based
on the problem being present at the time that the
test is run.All testing should be done with a
fully charged battery.
If the TCM records a DTC that will adversely
affect vehicle emissions, it will request (via the
communication bus) that the PCM illuminate the
Malfunction Indicator Lamp (MIL). Although theseDTC's will be stored in the TCM immediately as a 1
trip failure, it may take up to five minutes of
accumulated trouble confirmation set the DTC and
illuminate the MIL. Three consecutive successful
OBDII (EURO STAGE III OBD) trips or clearing
the DTC's with a diagnostic tool (DRBIIItor equiv-
alent) is required to extinguish the MIL. When the
TCM requests that the PCM illuminate the MIL,
the PCM sets a DTC P0700(89) to alert the techni-
cian that there are DTC's in the TCM. This must
also be erased in the PCM in order to extinguish the
MIL.
3.3.1 HARD CODE
Any Diagnostic Trouble Code (DTC) that is set
whenever the system or component is monitored is
a HARD code. This means that the problem is there
every time the TCM checks that system or compo-
nent. Some codes will set immediately at start up
and others will require a road test under specific
conditions. It must be determined if a code is
repeatable (Hard) or intermittent before attempt-
ing diagnosis.
3.3.2 ONE TRIP FAILURES
A One Trip Failure, when read from the TCM, is
a hard OBDII (EURO STAGE III OBD) code that
has not matured for the full 5 minutes. This applies
to codes that will only set after 5 minutes of
substituted gear operation.
3.3.3 INTERMITTENT CODE
A diagnostic trouble code that is not there every
time the TCM checks the circuit or function is an a
intermittent code. Some intermittent codes, such as
codes P1792(12), P1767(14), P1768(15), P0725(18),
P1716(19), P1781(21), P1782(22), P1724(24),
P0705(28), P0120(29), P0750(41), P0755(42),
P0760(43), P0765(44), P1793(48), P0715(56),
P0720(57), P1794(58), P1796(70), P1799(74),
P1739(76), P1717(77), and P0600(78) are caused by
wiring or connector problems. However intermit-
tent codes 50 - 54 are usually caused by intermit-
tent hydraulic seal leakage in the clutch and/or
accumulator circuits. Problems that come and go
like this are the most difficult to diagnose, they
must be looked for under the specific conditions
that cause them.
3.3.4 STARTS SINCE SET COUNTER
For the most recent code (Code 1), the Starts
Since Set counter counts the number of times the
vehicle has started since it was last set. The counter
will count up to 255 starts. Note that this code only
applies to the last code set.
When there are no diagnostic trouble codes stored
in memory, the DRBIIItwill display ``NO DTC'S
3
GENERAL INFORMATION

PRESENT'' and the reset counter will show
``STARTS SINCE CLEAR = XXX''.
The number of starts helps determine if the
diagnostic trouble code is hard or intermittent.
± If the count is less than 3, the code is usually a
hard code.
± If the count is greater than 3, it is considered
an intermittent code. This means that the
engine has been started most of the time
without the code recurring.
3.3.5 TROUBLE CODE ERASURE
A Diagnostic trouble code will be cleared from
TCM memory if it has not reset for 40 warm-up
cycles.A warm-up cycle is defined as sufficient vehicle
operation such that the coolant temperature has
risen by at least 4.4C (40ÉF) from engine starting
and reaches a minimum temperature of 71C
(160ÉF).
The Malfunction Indicator Lamp (MIL) will turn
off after 3 good trips or when the DTC's are cleared
from the TCM.
3.3.6 LIST OF DIAGNOSTIC TROUBLE
CODES
(Detailed descriptions follow list)
The TCM may report any of the following DTC's.
DTC P-Code Name of Code Limp-in MIL
11 P0700 Internal TCM Yes Yes
12 P1792 Battery was disconnected No No
13 P0700 Internal TCM Yes Yes
14 P1767 Relay output always on Yes Yes
15 P1768 Relay output always off Yes Yes
16 P0605 Internal TCM Yes Yes
17 P0604 Internal TCM Yes Yes
18 P0725 Engine speed input circuit Yes Yes
19 P1716 Bus communication with engine module No No
20 P1765 Switched battery (Trans Relay Output) Yes Yes
21 P1781 OD pressure switch sense circuit Yes Yes
22 P1782 2-4 pressure switch sense circuit Yes Yes
24 P1784 L-R pressure switch sense circuit Yes Yes
28 P0705 Check shifter signal No No
29 P0120 Throttle position sensor signal circuit No No
31 P1787 OD hydraulic pressure switch circuit Yes Yes
32 P1728 24 hydraulic pressure switch circuit Yes Yes
33 P1728 OD/24 hydraulic pressure switch circuit Yes Yes
35 P1791 Loss of prime No No
36 P1790 Fault immediately after shift No No
37 P1775 Solenoid switch valve latched in TCC position No Yes
38 P0740 Torque converter clutch control circuit No Yes
45 P1795 Internal TCM No No
47 P1776 Solenoid switch valve latched in L-R position Yes Yes
48 P1793 TRD link communication error No No/Yes (3.3L-3.5L)
50 P0736 Gear ratio error in reverse Yes Yes
51 P0731 Gear ratio error in 1st Yes Yes
52 P0732 Gear ratio error in 2nd Yes Yes
53 P0733 Gear ratio error in 3rd Yes Yes
54 P0734 Gear ratio error in 4th Yes Yes
56 P0715 Input speed sensor error Yes Yes
57 P0720 Output speed sensor error Yes Yes
58 P1794 Speed sensor ground error Yes Yes
70 P1796 Autostick sensor circuit No No
4
GENERAL INFORMATION

> Transmission Simulator (Miller # 8333)
> Transmission Simulator (Miller # 8333-1)
Adapter harness kit and panel overlay for FWD
vehicles.
> Jumper wires
> Test Light (minimum of 25 ohms of resistance)
> Ohmmeter
> Voltmeter
> Pressure gauge (0-300 PSI)
6.0 GLOSSARY OF TERMS
6.1 ACRONYMS
BCMBody Control Module
CKTCircuit
CVIClutch Volume Index
DLCData Link Connector
DRBIIItDiagnostic Readout Box
DTCDiagnostic Trouble Code
EATXElectronic Automatic Transaxle
EMCCElectronically Modulated Converter
Clutch
FCMFront Control Module (part of the
IPM system)
IODIgnition off-draw
IPMIntelligent Power Module
IRTIntelligent Recovery Timer
ISSInput Speed Sensor
LEDLight Emitting Diode
LRLow/reverse Clutch or Pressure
Switch
LULockupMICMechanical Instrument Cluster
MILMalfunction Indicator Lamp
OBDIIOn Board Diagnostics
ODOverdrive Clutch or Pressure
Switch
OSSOutput Speed Sensor
PCMPowertrain Control Module
PEMCCPartial Electronically Modulated
Converter Clutch
PLUPartial Lockup
REVReverse Clutch
SLPKSolenoid Pack
SSVSolenoid Switch Valve
SWSwitch
TCCTorque Converter Clutch
TCMTransmission Control Module
TPThrottle Position
TRDTorque Reduction
TRSTransmission Range Sensor
UDUnderdrive Clutch
2-42nd and 4th gear Clutch or Pres-
sure Switch
6.2 DEFINITIONS
OBDII (EURO STAGE III OBD) Trip - A vehicle
start and drive cycle such that all once per trip
diagnostic monitors have run.
Key Start - A vehicle start and run cycle of at least
20 seconds.
Warm-up Cycle - A vehicle start and run cycle
such that the engine coolant must rise to at least
71C (160ÉF) and must rise by at least 4.4C (40ÉF)
from initial start up. To count as a warm-up cycle,
no DTC may occur during the cycle.
21
GENERAL INFORMATION