fuel CHRYSLER VOYAGER 2001 Service Manual

Symptom List:
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0462-FUEL LEVEL SENDING
UNIT VOLTS TOO LOW.
When Monitored and Set Condition:
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW
When Monitored: Ignition on and battery voltage above 10.4 volts.
Set Condition: The fuel level sensor signal voltage goes below 0.4 volts for more than 90
seconds.
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
When Monitored: Ignition on and battery voltage above 10.4 volts.
Set Condition: The fuel level sensor signal voltage at the PCM goes above 9.9 volts for
more than 90 seconds.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
INTERMITTENT CONDITION
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®Refer to the Instrument Category and perform the appropriate
symptoms.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 2
145
DRIVEABILITY - GAS

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.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
NOTE: Phsyically and Visually inspect the fuel tank for damage. if a
problem is found repair or replace as necessary.
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 - 5.
No®Test Complete.
146
DRIVEABILITY - GAS
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW ÐContinued

Symptom:
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR
When Monitored and Set Condition:
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR
When Monitored: With the engine running, coolant greater than 70ÉC (158ÉF), open
throttle, steady to slightly increasing vehicle speed greater than 18 mph but less than 55
mph, with a light load on the engine, for a period no less than 5 minutes.
Set Condition: The oxygen sensor signal voltage is switching from below 0.39 volt to
above 0.6 volts and back fewer times than required.
POSSIBLE CAUSES
INTERMITTENT CONDITION
EXHAUST LEAK
O2 SENSOR SIGNAL CIRCUIT VOLTAGE DROP
O2 SENSOR GROUND CIRCUIT VOLTAGE DROP
O2 SENSOR
TEST ACTION APPLICABILITY
1NOTE: Check for contaminates that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
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 6
2 Start the engine.
Inspect the exhaust for leak between the engine and the O2 sensor.
Inspect the exhaust for leaks between the engine and the appropriate rear O2 Sensor.
Are there any exhaust leaks?All
Ye s®Repair or replace the leaking exhaust parts as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
178
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3NOTE: 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 O2 Sensor Signal circuit at the O2 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 4
No®Repair the high resistance on the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
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 O2 Sensor ground circuit at the O2 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 on the O2 Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5 If there are no possible causes remaining, view repair. All
Repair
Replace the O2 Sensor
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6NOTE: Check for contaminates that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
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.
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 - 5.
No®Test Complete.
179
DRIVEABILITY - GAS
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR ÐContinued

Symptom:
P1282-FUEL PUMP RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1282-FUEL PUMP RELAY CONTROL CIRCUIT
When Monitored: With the ignition on. Battery voltage greater than 10.4 volts.
Set Condition: An open or shorted condition is detected in the fuel pump relay control
circuit.
POSSIBLE CAUSES
FUEL PUMP RELAY INTERMITTENT OPERATION
INTERMITTENT CONDITION
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
INTELLIGENT POWER MODULE
FUEL PUMP RELAY
IPM FUSE & RELAY CENTER
FUEL PUMP RELAY CONTROL CIRCUIT OPEN
FUEL PUMP RELAY CONTROL CIRCUIT SHORT TO GROUND
PCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, actuate the Fuel Pump Relay.
Is the Fuel Pump Relay operating?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition on.
With the DRBIIIt, actuate the Fuel Pump Relay.
Wiggle the wiring harness from the Fuel Pump Relay to the PCM while the relay is
actuating.
Did the Fuel Pump Relay stop when wiggling the wiring harness?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
181
DRIVEABILITY - GAS

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 - 5.
No®Test Complete.
4 Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 5
No®Go To 10
5 Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the Fuel Pump Relay Control
circuit in the IPM.
With the DRBIIIt, actuate the Fuel Pump Relay.
Does the test light flash on and off?All
Ye s®Replace the Fuel Pump Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 6
6 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the Fuel Pump Relay Control
circuit in the IPM harness connector..
With the DRBIIIt, actuate the Fuel Pump Relay.
Does the test light flash on and off?All
Ye s®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 7
182
DRIVEABILITY - GAS
P1282-FUEL PUMP RELAY CONTROL CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Fuel Pump Relay Control circuit between the
Intelligent Power Module C3 harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 8
No®Repair the Fuel Pump Relay Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
8 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Fuel Pump Relay Control circuit in the Intelligent
Power Module C3 harness connector to ground.
Is the resistance below 5.0 ohms.All
Ye s®Repair the Fuel Pump Relay Control circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 9
9 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.
10 Turn the ignition off.
Disconnect the Intelligent Power Module C9 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM harness connector.
Does the test light illuminate?All
Ye s®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
183
DRIVEABILITY - GAS
P1282-FUEL PUMP RELAY CONTROL CIRCUIT ÐContinued

Symptom:
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored and Set Condition:
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
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: LDP Switch does not reach at least 3 closures with 10 seconds. LDP must
initial in normal conditions to mature failure.
POSSIBLE CAUSES
INTERMITTENT LDP MONITOR FAILURE
OBSTRUCTION IN EVAP SYSTEM BETWEEN EVAP CANISTER AND FUEL TANK
EVAP CANISTER OBSTRUCTED
OBSTRUCTION IN HOSE/TUBE BETWEEN EVAP CANISTER AND PURGE SOLENOID
LDP PRESSURE HOSE OBSTRUCTED
LEAK DETECTION PUMP
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 6
207
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
2 To continue testing you will need Miller Tools #6872A Evap System Pressure Pump
and #8382 Gas Cap Tester Adapter.
WARNING: The test equipment is designed to be used to pressurize the
vehicles Evaporative System only. Using the equipment in a manner for
which it was not designed could be harmful.
Warning: Keep lighted cigarettes, sparks, flames, and other ignition sources
away from the test area to prevent the ignition of explosive gases. Keep the
test area well ventilated.
Note: The fuel tank should have between 20% & 80% of full to properly test
the Evap system.
Attach the power source red clip of Miller Tool #6872A to Battery (+) and the ground
black clip to Battery (-).
Perform the Evaporative System Pressure Pump self test that is specified on the
tester cover.
Remove gas cap and install Miller Tool #8382 on vehicle. Install gas cap to Miller Tool
#8382. Attach the pressure supply hose from Miller Tool #6872A to the fitting on
#8382.
Disconnect the vacuum supply hose at the Leak Detection Pump. Connect and apply
a continuous vacuum supply (i.e. 209Hg) to the Leak Detection Pump. A vacuum
pump such as an A/C recovery unit works well.
Turn the ignition on.
With the DRBIIItin System Tests, select Leak Detect Pump Test. Read instructions
and then press Enter. Select: #3 - HOLD PSI.
On Miller Tool #6872A, set the Pressure/Hold switch to Open and set the Vent switch
to Closed. Turn the pump timer On and watch the gauge.
When the gauge pressure reaches 149H2O, turn the Pressure/Hold Valve to Closed.
Turn the pump timer off.
Disconnect the hose at the EVAP Canister that goes to the Fuel Tank.
Did the pressure drop when the hose was disconnected?All
Ye s®Go To 3
No®Repair obstruction in the EVAP system between the EVAP
Canister and the fuel tank.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
3Note: All previously disconnected hose(s) reconnected.
Re-pressurize the EVAP System. On Miller Tool #6872A, set the Pressure/Hold
switch to Open and set the Vent switch to Closed. Turn the pump timer On and watch
the gauge.
When the gauge pressure reaches 149H2O, turn the Pressure/Hold Valve to Closed.
Turn the pump timer off.
Disconnect the LDP Pressure hose at the EVAP Canister. The LDP Pressure hose is
the hose that connects the Evap Canister to the Leak Detection Pump.
Did the pressure drop when the hose was disconnected?All
Ye s®Go To 4
No®Replace the EVAP Canister.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
208
DRIVEABILITY - GAS
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND ÐContinued

TEST ACTION APPLICABILITY
4Note: All previously disconnected hose(s) reconnected.
Re-pressurize the EVAP System. On Miller Tool #6872A, set the Pressure/Hold
switch to Open and set the Vent switch to Closed. Turn the pump timer On and watch
the gauge.
When the gauge pressure reaches 149H2O, turn the Pressure/Hold Valve to Closed.
Turn the pump timer off.
Disconnect the EVAP hoses at the Purge Solenoid.
Did the pressure drop when the hose was disconnected?All
Ye s®Go To 5
No®Repair or replace hose/tube as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
5 Disconnect and remove the LDP pressure hose. The LDP pressure hose is the hose
that connects the EVAP Canister to the Leak Detection Pump.
Inspect the LDP pressure hose for any obstructions or physical damage.
Is the LDP pressure hose free from defects?All
Ye s®Replace the Leak Detection Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No®Repair/replace hose as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
6 At this time, the conditions required to set the DTC are not present.
Note: Use the Freeze Frame Data to help you duplicate the conditions that
set the DTC. Pay particular attention to the DTC set conditions, such as,
VSS, MAP, ECT, and Load.
Note: A thorough visual inspection of the Evap system hoses, tubes, and
connections may save time in your diagnosis. Look for any physical damage
or signs of wetness at connections. The strong smell of fuel vapors may aid
diagnosis also.
Note: Refer to any Technical Service Bulletins (TSB's) that may apply.
With the DRBIIItin System Tests, perform the LDP Monitor Test. This will force the
PCM to run the LDP Monitor. If the monitor fails, further diagnosis is required to
find faulty component. If the monitor passes, the condition is not present at this time.
Were any problems found?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No®Test Complete.
209
DRIVEABILITY - GAS
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND ÐContinued