ignition CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
8 Turn the ignition off.
Disconnect the MAF Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Sensor Ground circuit between the MAF Sensor and
the ECM.
Is the resistance below 10.0 ohms?All
Ye s®Go To 9
No®Repair the Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
9 Turn the ignition off.
Disconnect the MAF Sensor harness connector.
Measure the voltage between the 5-volt Supply circuit and the Sensor Ground circuit
at the MAF Sensor harness connector.
Is the voltage above 4.5 volts?All
Ye s®Go To 10
No®Replace and program the ECM in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
10 Turn the ignition off.
Disconnect the MAF Sensor harness connector.
With the DRBIIIt, actuate the ECM/PCM Relay.
Measure the voltage of the 12-volt Supply circuit at the MAF Sensor harness
connector
Is the voltage above 10.0 volts?All
Ye s®Go To 11
No®Repair the ECM/PCM Relay Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
11 Turn the ignition off.
NOTE: Inspect the turbocharger inlet tube between the MAF Sensor and the
Turbocharger. Ensure the airflow tube properly is secured at each end and
that there is no damage, restrictions or air leaks in the tube.
With a voltmeter, backprobe the MAF Sensor Signal circuit at the MAF Sensor
harness connector.
Allow the engine to idle for at least 2 minutes.
NOTE: The engine speed must be approximately 900 rpm for this test to be
valid.
Is the voltage between 2.1 and 2.7 volts?All
Ye s®Go To 12
No®Replace the Mass Air Flow Sensor in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
16
DRIVEABILITY - DIESEL
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
12 Turn the ignition off.
NOTE: Inspect the turbocharger inlet tube between the MAF Sensor and the
Turbocharger. Ensure the airflow tube properly is secured at each end and
that there is no damage, restrictions or air leaks in the tube.
With a voltmeter, backprobe the MAF Sensor Signal circuit at the MAF Sensor
harness connector.
With the engine at operating temperature, depress the throttle completely to the Full
throttle position for 5 seconds and note the voltmeter reading.
Is the voltage between 3.1 and 3.7 volts?All
Ye s®Test Complete.
No®Replace the Mass Air Flow Sensor in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
13 Turn the ignition off.
Disconnect the MAF 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 14
No®Repair the 5-volt Supply circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
14 Turn the ignition off.
Disconnect the MAF Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the 5-volt Supply circuit and the Sensor Ground
circuit at the MAF Sensor harness connector.
Is the resistance above 1000 ohms?All
Ye s®Go To 15
No®Repair the 5-volt Supply circuit for a short to the Sensor Ground
circuit.
Perform ROAD TEST VERIFICATION - VER-2.
15 Turn the ignition off.
Disconnect the MAF Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the 5-volt Supply circuit at the MAF
harness connector.
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 16
17
DRIVEABILITY - DIESEL
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
16 Turn the ignition off.
Disconnect the MAF 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®Go To 17
17 Turn the ignition off.
Disconnect the Fuel Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the 5-volt Supply circuit and the Sensor Ground
circuit at the Fuel Pressure Sensor harness connector.
Is the resistance above 1000 ohms?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 Fuel Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the 5-volt Supply circuit at the Fuel
Pressure Sensor harness connector.
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 Fuel Pressure 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 Fuel Pressure Sensor 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.
18
DRIVEABILITY - DIESEL
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY ÐContinued

Symptom List:
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO
HIGH
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO
LOW
P0606-ECM ERROR GATE ARRAY - COMMUNICATION
P0606-ECM ERROR GATE ARRAY - COMMUNICATION NOT VERI-
FIED
P0606-ECM ERROR GATE ARRAY - QUANTITY STOP
P0606-ECM ERROR RECOVERY HAS OCCURRED
P0606-ECM ERROR REDUNDANT OVERRUN MONITORING
P1206-CALCULATED INJECTOR VOLTAGE TOO HIGH
P1206-CALCULATED INJECTOR VOLTAGE TOO LOW
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW
P1606-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE
P1606-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR
P1680-EEPROM PLAUSIBILITY CODE WORD INCORRECT OR
MISSING
P1680-EEPROM PLAUSIBILITY COMMUNICATION ERROR
P1680-EEPROM PLAUSIBILITY VARIATION NUMBER ERROR
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR
P1680-EEPROM PLAUSIBILITY WRITE ERROR
P1696-EEPROM MEMORY WRITE DENIED
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0105-BAROMETRIC PRES-
SURE CIRCUIT SIGNAL VOLTAGE TOO HIGH.
When Monitored and Set Condition:
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH
When Monitored: With the ignition on.
Set Condition: The Barometric Pressure Sensor Signal is above 4.75 volts.
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW
When Monitored: With the ignition on.
Set Condition: The Barometric Pressure Sensor Signal is below 0.66 volt.
20
DRIVEABILITY - DIESEL

P0606-ECM ERROR GATE ARRAY - COMMUNICATION
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P0606-ECM ERROR GATE ARRAY - COMMUNICATION NOT VERIFIED
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P0606-ECM ERROR GATE ARRAY - QUANTITY STOP
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P0606-ECM ERROR RECOVERY HAS OCCURRED
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P0606-ECM ERROR REDUNDANT OVERRUN MONITORING
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH
When Monitored: With the engine running. During every 180É of engine rotation.
Set Condition: The ECM determines that the capacitor voltage is out of range.
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW
When Monitored: With the engine running. During every 180É of engine rotation.
Set Condition: The ECM determines that the capacitor voltage is out of range.
P1606-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE
When Monitored: At ignition off.
Set Condition: The ECM detects the engine speed has not fallen below 650 RPM within
0.5 seconds after ignition off.
P1606-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY
When Monitored: At ignition off.
Set Condition: The ECM detects the engine speed has not fallen below 650 RPM within
0.5 seconds after ignition off.
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
21
DRIVEABILITY - DIESEL
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO
HIGH Ð
Continued

P1680-EEPROM PLAUSIBILITY CODE WORD INCORRECT OR MISSING
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P1680-EEPROM PLAUSIBILITY COMMUNICATION ERROR
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P1680-EEPROM PLAUSIBILITY VARIATION NUMBER ERROR
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P1680-EEPROM PLAUSIBILITY WRITE ERROR
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
P1696-EEPROM MEMORY WRITE DENIED
When Monitored: With the ignition on.
Set Condition: The ECM detects an internal failure.
POSSIBLE CAUSES
ENGINE CONTROL MODULE
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1NOTE: This DTC indicates an internal ECM problem.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Perform several engine run cycles, turning the ignition off for at least 20 seconds
between each engine run cycle.
With the DRBIIIt, read the ECM DTC's.
Did this DTC reset?All
Ye s®Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 2
22
DRIVEABILITY - DIESEL
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO
HIGH Ð
Continued

Symptom:
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE
TOO HIGH
When Monitored and Set Condition:
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH
When Monitored: With the ignition on.
Set Condition: The Intake Air Temperature Sensor Signal voltage is above 4.85 volts.
POSSIBLE CAUSES
INTERMITTENT CONDITION
INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
INTAKE AIR TEMP SENSOR GROUND CIRCUIT OPEN
INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT OPEN
TURBOCHARGER BOOST PRESSURE/IAT SENSOR
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRB, erase ECM DTCs.
Monitor the DRB for ECM DTCs.
Did this DTC reset?All
Ye s®Go To 2
No®Go To 6
2 Turn the ignition off.
Disconnect the Turbocharger Boost Pressure/IAT 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 on the IAT Sensor Signal circuit.
Is the voltage below 1.0 volt?All
Ye s®Go To 3
No®Repair the Intake Air Temperature Sensor Signal circuit for a
short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
NOTE: Remove the jumper wire.
24
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Boost Pressure/IAT Sensor harness connector.
Measure the resistance of the Intake Air Temperature Sensor Signal circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the Intake Air Temperature Sensor Signal circuit for an
open.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Disconnect the Boost Pressure/IAT Sensor harness connector.
Connect a jumper wire between the IAT Sensor Signal and IAT Sensor Ground
circuits in the Boost Pressure/IAT Sensor harness connector.
Turn the ignition on.
Monitor the DRB for ECM DTCs.
Does the DRB display P0110 INTAKE AIR TEMP. SENSOR CIRCUIT SIGNAL
VOLTAGE TOO LOW?All
Ye s®Replace the Turbocharger Boost Pressure/Intake Air Tempera-
ture Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 5
5 Turn the ignition off.
Disconnect the Boost Pressure/IAT Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Sensor Ground circuit between the ECM harness
connector and the Boost Pressure Sensor harness connector.
Monitor the DRB for ECM DTCs.
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 Intake Air Temperature Sensor Ground circuit for an
open.
Perform ROAD TEST VERIFICATION - VER-2.
25
DRIVEABILITY - DIESEL
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO
HIGH Ð
Continued

Symptom:
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE
TOO LOW
When Monitored and Set Condition:
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW
When Monitored: With the ignition on.
Set Condition: The Intake Air Temperature Sensor Signal voltage is below 0.21 volt.
POSSIBLE CAUSES
INTERMITTENT CONDITION
INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
TURBOCHARGER BOOST PRESSURE/IAT SENSOR
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRB, erase ECM DTCs.
Monitor the DRB for ECM DTCs.
Did this DTC reset?All
Ye s®Go To 2
No®Go To 5
2 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Boost Pressure/IAT Sensor harness connector.
Measure the resistance between ground and the Intake Air Temperature Sensor
Signal circuit.
Is the resistance above 1000 ohms?All
Ye s®Go To 3
No®Repair the Intake Air Temperature Sensor Signal circuit for a
short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
3 Turn the ignition off.
Disconnect the Boost Pressure/IAT Sensor harness connector.
Turn the ignition on.
Monitor the DRB for ECM DTCs.
Does the DRB display P0110 INTAKE AIR TEMP SIGNAL VOLTAGE TOO HIGH?All
Ye s®Replace the Turbocharger Boost Pressure/Intake Air Tempera-
ture Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 4
27
DRIVEABILITY - DIESEL

Symptom:
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLT-
AGE TOO HIGH
When Monitored and Set Condition:
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO
HIGH
When Monitored: With the ignition on.
Set Condition: The Engine Coolant Temperature Sensor Signal voltage is above 4.95 volts
for more than 1 second.
POSSIBLE CAUSES
INTERMITTENT CONDITION
ECM ECT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECT SENSOR GROUND CIRCUIT OPEN
ECT SENSOR
ECT SENSOR SIGNAL CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: If multiple DTCs are present, the most likely cause is a 5-Volt Supply
or Sensor Ground circuit shorted to voltage or ground. Refer to the Service
Information Wiring section for circuits that would affect multiple DTCs.
Turn the ignition on.
With the DRB, monitor the Engine Coolant Temperature (ECT) Sensor voltage.
Is the ECT Sensor voltage above 4.5 volts?All
Ye s®Go To 2
No®Go To 7
2 Turn the ignition off.
Disconnect the ECT Sensor harness connector.
Turn the ignition on.
Measure the voltage on the ECT Sensor Signal circuit.
Is the voltage above 5.5 volts?All
Ye s®Repair the ECM ECT Sensor Signal circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 3
29
DRIVEABILITY - DIESEL