light CHRYSLER VOYAGER 2001 Service Manual

Symptom:
P0403 - EGR SOLENOID CIRCUIT
When Monitored and Set Condition:
P0403 - EGR SOLENOID CIRCUIT
When Monitored: Engine running. Battery voltage greater than 10 volts.
Set Condition: The EGR solenoid control circuit is not in the expected state when
requested to operate by the PCM.
POSSIBLE CAUSES
INTERMITTENT CONDITION
EGR SOLENOID
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EGR SOLENOID CONTROL CKT SHORTED TO VOLTAGE
EGR SOLENOID CONTROL CKT SHORT TO GND
EGR SOLENOID CONTROL CKT OPEN
PCM
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 8
2 Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Turn all accessories off.
Using a 12 volt Test Light connected to the Fused Ignition Switch Output circuit,
probe the EGR Solenoid Control circuit.
With the DRB, actuate the EGR solenoid.
Does the 12 volt test light flash on and off?All
Ye s®Inspect the EGR Valve Back Pressure hose and tube for obstruc-
tions or damage. If OK, replace the EGR Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
128
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3 Turn the igntion off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Using a 12 volt Test Light connected to ground, probe the Fused Ignition Switch
Output circuit in the EGR Solenoid harness connector.
Does the 12 volt test light illuminate?All
Ye s®Go To 4
No®Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4 Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Measure the voltage of the EGR Solenoid Control circuit in the EGR Solenoid
connector.
Is the voltage above 1.0 volt?All
Ye s®Repair the EGR Solenoid Control circuit for a short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 5
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the EGR Solenoid Control circuit in the EGR Solenoid
harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the EGR Solenoid Control circuirt for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 6
6 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the EGR Solenoid Control circuit between the PCM
harness connector and the EGR Solenoid harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the EGR Solenoid Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
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 - 5.
129
DRIVEABILITY - GAS
P0403 - EGR SOLENOID CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
1NOTE: A loose gas cap could have caused this DTC to set. Make sure gas cap
is tight and in good condition. Ensure the gas cap meets OEM specifications.
Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the DTC Specific Good Trip Counter displayed and equal to zero?All
Ye s®Go To 2
No®Go To 4
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% and 80% of fuel tank capacity
to properly test the Evap system.
Attach the power red source clip of Miller Tool #6872A to Battery (+) and the black
ground 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.
NOTE: If the pressure does not build up, there is obviously a large leak in
the system and the presence of strong fuel odor may be present. A visual
inspection should find a leak of substantial size.
When the gauge pressure reaches 149H2O, turn the Pressure/Hold Valve to Closed.
Turn the pump timer off. Note the time and pressure. After 10 sec of stabilization
time.
Did the pressure drop more than 69H2O in 2 minutes?All
Ye s®Go To 3
No®Go To 4
137
DRIVEABILITY - GAS
P0442-EVAP LEAK MONITOR MEDIUM (.040) LEAK DETECTED Ð
Continued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the IAC Motor harness connector.
Start and idle the engine.
Using a test light connected to ground, probe the IAC Driver #1 circuit for 10 seconds.
Repeat the above test for the remaining IAC Motor Driver circuits.
Does the test light turn on and off while probing each IAC Motor Driver circuit?2.4L 4 CYL DOHC
16V MPI
Ye s®Replace the Idle Air Control Motor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
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?2.4L 4 CYL DOHC
16V MPI
Ye s®Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
155
DRIVEABILITY - GAS
P0505-IDLE AIR CONTROL MOTOR CIRCUITS ÐContinued

Symptom:
P0703-BRAKE SWITCH SENSE CIRCUIT
When Monitored and Set Condition:
P0703-BRAKE SWITCH SENSE CIRCUIT
When Monitored: TEST #1: Vehicle speed greater than 17 MPH to enable. TEST #2:
Speed must be 0 and brake switch indicates on.
Set Condition: TEST #1: If vehicle speed goes to 0 MPH without brake input. Condition
must be repeated 9 times to set fault. Two trip fault. TEST #2: If vehicle speed go above 17
MHP for more than 6.4 seconds without a change in brake state. Condition must be repeat
9 times to set fault.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUSED B+ CIRCUIT
BRAKE SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE
BRAKE SWITCH SENSE SHORTED TO GROUND
BRAKE SWITCH SENSE CIRCUIT OPEN
GROUND CIRCUIT OPEN
BRAKE LAMP SWITCH OPERATION
PCM
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 9
2 Turn the ignition off.
Disconnect the Brake Lamp Switch harness connector.
Using a 12-volt test light connected to ground, check the Fused B+ circuit in the
Brake Lamp Switch harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Repair the Fuse B+ circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
162
DRIVEABILITY - GAS

Symptom:
P0743-TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY
CIRCUITS (3SP AUTO TRANS)
When Monitored and Set Condition:
P0743-TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIRCUITS
(3SP AUTO TRANS)
When Monitored: With the ignition on. Battery voltage greater than 10 volts
Set Condition: An open or shorted condition is detected in the torque converter clutch
solenoid control circuit.
POSSIBLE CAUSES
INTERMITTENT CONDITION
TCC SOLENOID
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
TCC SOLENOID CONTROL CKT SHORTED TO VOLTAGE
TCC SOLENOID CONTROL CKT SHORT TO GND
TCC SOLENOID CONTROL CKT OPEN
PCM
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 8
2 Turn the ignition on.
Turn all accessories off.
Disconnect the TCC Solenoid harness connector.
Using a 12 volt Test Light connected to the Fused Ignition Switch Output circuit,
probe the TCC Solenoid Control circuit.
With the DRB, actuate the TCC solenoid.
Does the 12 volt test light flash on and off?All
Ye s®Replace the TCC Solenoid.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
No®Go To 3
168
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3 Turn the igntion off.
Disconnect the TCC Solenoid harness connector.
Turn the ignition on.
Using a 12 volt Test Light connected to ground, probe the Fused Ignition Switch
Output circuit in the TCC Solenoid harness connector.
Does the 12 volt test light illuminate?All
Ye s®Go To 4
No®Repair the Fused Ignition Switch Output circuit for an open.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
4 Turn the ignition off.
Disconnect the TCC Solenoid harness connector.
Turn the ignition on.
Measure the voltage of the TCC Solenoid Control circuit in the TCC Solenoid
connector.
Is the voltage above 0.5 volts.All
Ye s®Repair the TCC Solenoid Control circuit for a short to voltage.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
No®Go To 5
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the TCC Solenoid harness connector.
Measure the resistance of the TCC Solenoid Control circuit in the TCC Solenoid
harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the TCC Solenoid Control circuirt for a short to ground.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
No®Go To 6
6 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the TCC Solenoid harness connector.
Measure the resistance of the TCC Solenoid Control circuit between the PCM
harness connector and the TCC Solenoid harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the TCC Solenoid Control circuit for an open.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
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 31TH TRANSMISSION VERIFICATION TEST - VER 1..
169
DRIVEABILITY - GAS
P0743-TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIR-
CUITS (3SP AUTO TRANS) Ð
Continued

TEST ACTION APPLICABILITY
6 Turn the ignition off.
Disconnect Clutch Pedal Position Switch harness connector.
Using a 12-volt test light connected to 12-volts, probe the ground circuit in the Clutch
Pedal Position Switch harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 7
No®Repair the ground circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
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 - 5.
173
DRIVEABILITY - GAS
P0833-CLUTCH RELEASED SWITCH CIRCUIT 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
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