2000 CHRYSLER VOYAGER Diagnostic Manual

Symptom:
P-0401 EGR SYSTEM FAILURE
When Monitored and Set Condition:
P-0401 EGR SYSTEM FAILURE
When Monitored: With engine temp > than 82 degrees C (180 degrees F), ambient temp
> 4 degrees C (40 degrees F), engine in closed loop, O2 Sensor operational, engine under a
steady load with throttle open, and O2 Controller not at or near its limits.
Set Condition: If all conditions met, turn EGR off & on. O2 Snsr Sig is monitored for
change in output sig. If no major change or too much change, flag is set. Repeat test up to
3x in run cycle (2 trips). If fails every time, code sets. If any pass, diags are suspended.
POSSIBLE CAUSES
EXHAUST LEAK
INTAKE MANIFOLD RESTRICTED
EGR BACK PRESSURE TRANSDUCER DEFECTIVE
EGR VALVE ASSEMBLY DEFECTIVE
EGR VALVE ASSEMBLY MOUNTED INCORRECTLY
EGR SYSTEM FAILURE DOES NOT REOCCUR
EGR TRANSDUCER LINE BLOCKED
EGR VALVE ASSEMBLY DIAPHRAM DEFECTIVE
VACUUM SUPPLY TO EGR SOLENOID INADEQUATE
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the EGR System Failure does not exist or is an intermittent problem.
With the DRB, read the FREEZE FRAME.
With this screen, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME, pay particular attention to the fault setting condi-
tions, such as speed, temp, load, and map vacuum.
Does the EGR System Failure reoccur?All
Ye s®Go To 3
No®EGR System Failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
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TEST ACTION APPLICABILITY
3 Turn off all accessories.
Start engine, allow engine to reach normal operating temperature.
Disconnect the Vacuum Supply Hose to the EGR Solenoid.
Connect a vacuum gauge to the disconnected hose.
Does the gauge read over 109of vacuum?All
Ye s®Go To 4
No®Repair the Vacuum Supply to the EGR Solenoid.
Perform VERIFICATION TEST VER-5A3.
4 Engine still running.
Reconnect the Vacuum Hose to the EGR Solenoid.
Disconnect the vacuum hose to the EGR Valve.
Connect a vacuum gauge to the disconnected hose.
Does the gauge pulsate?All
Ye s®Go To 5
No®Go To 7
5 While observing gauge, momentarily raise engine speed above 2000 rpm.
Did vacuum stabilize?All
Ye s®Go To 6
No®Replace EGR Valve Assembly.
Perform VERIFICATION TEST VER-5A3.
6 Remove the EGR Valve and inspect manifold and tube for restrictions.
Were any restrictions found?All
Ye s®Repair or replace as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Replace EGR Valve Assembly.
Perform VERIFICATION TEST VER-5A3.
7 Check for sizeable exhaust leak.
Were any leaks found?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Go To 8
8 Engine Running.
Disconnect Back Pressure Hose from Transducer.
Connect a pressure gauge to the Back Pressure Hose.
Is pressure gauge pulsating?All
Ye s®Replace EGR Assembly.
Perform VERIFICATION TEST VER-5A3.
No®Go To 9
9 Check EGR Back Mount. Check Valve tightness. Check EGR Valve Gasket.
Were any problems found?All
Ye s®Repair or replace as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Replace EGR Valve Assembly.
Perform VERIFICATION TEST VER-5A3.
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P-0401 EGR SYSTEM FAILURE ÐContinued
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Symptom:
P-0403 EGR SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0403 EGR SOLENOID CIRCUIT
When Monitored: With the ignition key on and engine running and battery voltage > 10
volts.
Set Condition: The EGR solenoid control circuit is not in the expected state when
requested to operate by the PCM.
POSSIBLE CAUSES
EGR SOLENOID DEFECTIVE
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EGR SOLENOID CIRCUIT WIRING HARNESS INTER DEFECT
EGR SOLENOID CIRCUIT WIRING HARNESS OBSERVABLE DEF
EGR SOLENOID CONTROL CIRCUIT OPEN
EGR SOLENOID CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE (EGR SOL CKT)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the codes.
Is the Global Good Trip displayed and equal to 0?All
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Turn ignition on with engine not running.
Using the DRB, actuate the EGR Solenoid.
Using a Voltmeter, probe the Fused Ignition Switch Output Circuit at the EGR
Solenoid Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 3
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-2A.
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TEST ACTION APPLICABILITY
3 Ignition Off
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the EGR Solenoid.
Is the resistance between 25.0 and 50.0 ohms?All
Ye s®Go To 4
No®Replace the EGR Solenoid.
Perform Powertrain Verification Test VER-2A.
4 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the EGR Solenoid Control Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open EGR Solenoid Control Circuit.
Perform Powertrain Verification Test VER-2A.
5 Ignition Off
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the EGR Solenoid Connector.
Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the EGR Solenoid Control Circuit at the EGR Solenoid
Connector to a good ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the EGR Solenoid Control Circuit short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 Ignition Off
If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-2A.
7 Ignition On, Engine Not Running
With the DRB, actuate the EGR Solenoid.
Wiggle Wiring Harness from the Solenoid to PCM.
Feel the EGR Assembly.
Does the EGR Solenoid stop actuating?All
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
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P-0403 EGR SOLENOID CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Using the schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Test Complete.
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P-0403 EGR SOLENOID CIRCUIT ÐContinued
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Symptom:
P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored and Set Condition:
P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored: After engine warm up to 63 degrees C (147 degrees F), 180 seconds of
open throttle operation, at a speed greater than 30 Km/h (20 mph), with the engine at
1200-1700 rpm and MAP vacuum between 15.0 and 21.0 inches of mercury (Hg).
Set Condition: As catalyst efficiency deteriorates, the switch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. If at any point during the test the
switch ratio reaches a predetermined value a counter is incremented by one.
POSSIBLE CAUSES
EXHAUST LEAK
ENGINE MECHANICAL PROBLEM
CATALYTIC CONVERTER DEFECTIVE
UPSTREAM O2 SENSOR OLDER THAN DOWNSTREAM O2 SENSOR
CATALYST EFFICIENCY FAILURE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIPS counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the Catalyst Efficiency Failure does not exist or is an intermittent
problem.
With the DRB, read the FREEZE FRAME DATA.
With this screen, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME DATA pay particular attention to the fault setting
conditions, such as speed, temp, load, and map vacuum.
Does the Catalyst Efficiency Failure Reoccur?All
Ye s®Go To 3
No®The Catalytic Conveter Efficiency Failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
3 Start Engine and let idle.
Check for exhaust leaks between the Engine and the appropriate Downstream O2
Sensor.
Are there any exhaust leaks?All
Ye s®Repair or replace leaking exhaust parts as necessary.
Perform VERIFICATION TEST VER-5A3.
No®Go To 4
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TEST ACTION APPLICABILITY
4NOTE: Check the exhaust for excessive smoke from internal oil or coolant
leaks.
Is there an oil or coolant consumption condition present?All
Ye s®Repair engine mechanical as necessary and replace Catalytic
Converter.
Perform VERIFICATION TEST VER-5A3.
No®Go To 5
5NOTE: A new Downstream O2 Sensor along with an aging Upstream O2
Sensor may cause this trouble code to set.
Review vehicle repair history.
Has the Downstream O2 Sensor been replaced without replacing the Upstream O2
Sensor?All
Ye s®Replace the appropriate Upstream Oxygen Sensor.
Perform VERIFICATION TEST VER-5A3.
No®Replace the Catalytic Converter.
Perform VERIFICATION TEST VER-5A3.
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P-0420 1/1 CATALYTIC CONVERTER EFFICIENCY ÐContinued
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Symptom:
P-0441 EVAP PURGE FLOW MONITOR FAILURE
When Monitored and Set Condition:
P-0441 EVAP PURGE FLOW MONITOR FAILURE
When Monitored: With engine temperature greater than 170ÉF, engine in closed loop,
engine idling for 2 minutes, no low fuel, MAP less than 15.7 inches mercury, and
barometric altitude less than 8,000 feet.
Set Condition: Note: with LDP: must pass stricter evap system test first. No air flow
through the evaporative system is detected by the evap monitor.
POSSIBLE CAUSES
PURGE CANISTER LINE DAMAGED
PURGE SOLENOID AND CANISTER DEFECTIVE
PURGE SOLENOID DEFECTIVE
VACUUM HOSES DAMAGED OR PLUGGED
EVAP PURGE MONITOR FAILURE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the Evap Purge Flow Monitor Failure does not exist or is an intermittent
problem.
With the DRB, read the FREEZE FRAME DATA.
With these screens, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME pay particular attention to the fault setting condi-
tions, such as speed, temp, load, and map vacuum.
Does the Evap Purge Flow Monitor Failure reoccur?All
Ye s®Go To 3
No®The Evap Purge Flow Monitor failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
3NOTE: Carefully inspect all vacuum hoses for proper routing and for
pinched or plugged hoses from the engine to the solenoid to the gas tank.
Are all vacuum hoses OK?All
Ye s®Go To 4
No®Repair the vacuum hoses as necessary.
Perform VERIFICATION TEST VER-5A3.
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