2000 CHRYSLER VOYAGER Diagnostic Manual

TEST ACTION APPLICABILITY
4 Remove Purge Solenoid and tap the ports against a clean solid surface.
Did any foreign material fall out?All
Ye s®Go To 5
No®Replace the Purge Solenoid.
Perform VERIFICATION TEST VER-5A3.
5 Inspect the line from the Purge Solenoid to the Canister.
Is the line disconnected, ripped, or cut?All
Ye s®Repair the line and replace Purge Solenoid.
Perform VERIFICATION TEST VER-5A3.
No®Clean out line and replace Purge Solenoid and Canister.
Perform VERIFICATION TEST VER-5A3.
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P-0441 EVAP PURGE FLOW MONITOR FAILURE ÐContinued
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Symptom List:
P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED
P-0455 EVAP LEAK MONITOR LARGE LEAK DETECTED
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P-0442 EVAP LEAK MONITOR
SMALL LEAK DETECTED.
When Monitored and Set Condition:
P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED
When Monitored: See DRB III.
Set Condition: See DRB III.
P-0455 EVAP LEAK MONITOR LARGE LEAK DETECTED
When Monitored: See DRB III.
Set Condition: See DRB III.
POSSIBLE CAUSES
EVAP SYSTEM HOSES OR WIRING DAMAGED
EVAP SYSTEM COMPONENT LEAKING
LEAK DETECTION PUMP LEAKING
EVAP LEAK MONITOR SMALL OR LARGE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1NOTE: Replacing the Powertrain Control Module will not correct this
problem.
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 conditions required to set this DTC are not present.
With the DRB, perform the LDP Monitor Test.
Follow the instructions on the DRB and allow the PCM to run the monitor.
After the monitor has finished running, does the DRB show ªTEST FAILED THIS
TRIP : YES'' on the monitor screen?All
Ye s®Go To 3
No®The Evap Leak Monitor DTC is not present at this time.
Perform VERIFICATION TEST VER-6A.
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TEST ACTION APPLICABILITY
3Note: Leaving the Gas Cap loose could cause this trouble code to set.
To continue testing you will need Miller Tool Kit #6872A and #8382.
NOTE: The Fuel Tank must have 1/2 tank of fuel to perform this test.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Warning: Verify the vehicle fuel tank contains at least 3 gallons of fuel.
Attach the DRB III to the vehicle.
Turn the Key On.
At: ENGINE SYSTEM TESTS select: LEAK DETECTION PUMP TEST.
Read instructions and then press ENTER.
At: LEAK DETECTION PUMP TEST select #3 HOLD PSI.
At the vacuum hose going to the LDP, attach and apply a continuous vacuum (i.e. 209
Hg).
Remove Gas Cap.
Install 8382 on the Gas Cap and on the vehicle.
Attach the supply hose from 6872A to 8382.
Attach the power source from the 6872A, clip to Battery(+) and ground clip to
Battery(-).
On the 6872A set the Pressure/Hold Valve to Open and set the Vent Valve to Closed.
Turn the timer on and watch the gauge.
When the gauge pressure reaches 14 in. H2O, turn the Pressure/Hold Valve to
Closed.
Turn the timer off. Note the time and pressure.
Did pressure drop more than 6 in. H2O (to 8 inches H2O on the gauge) in two
minutes?All
Ye s®Go To 4
No®Go To 5
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P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED ÐContinued
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TEST ACTION APPLICABILITY
4 To continue testing you will need Miller Tool Kit #6872A, #8382 and #6904 Ultrasonic
Leak Detector.
NOTE: The Fuel Tank must have 1/2 tank of fuel to perform this test.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Warning: Verify the vehicle fuel tank contains at least 3 gallons of fuel.
Attach the DRB III to the vehicle.
Turn the Key On.
At: ENGINE SYSTEM TESTS select: LEAK DETECTION PUMP TEST.
Read instructions and then press ENTER.
At: LEAK DETECTION PUMP TEST select #3 HOLD PSI.
At the vacuum hose going to the LDP, attach and apply a continuous vacuum (i.e. 209
Hg).
Remove Gas Cap.
Install 8382 on the Gas Cap and on the vehicle.
Attach the supply hose from 6872A to 8382.
Attach the power source from the 6872A, clip to Battery(+) and ground clip to
Battery(-).
Set Pressure Hold to Open and set Vent to Open.
Turn Pump Timer On.
To prevent noise from interfering with test, move tool #6872 away from vehicle.
Using the Ultrasonic Leak Detector, start listening for leaks at Gas Cap then proceed
to Rollover Valve, Canister, Leak Detection Pump, and Evap Purge Solenoid.
Were any leaks heard with the Ultrasonic Leak Detector?All
Ye s®Repair or replace leaking component.
Perform VERIFICATION TEST VER-6A.
No®Replace Leak Detection Pump.
Perform VERIFICATION TEST VER-6A.
5 At this time, the condition required to set the code is not present.
Using the schematic as a guide, inspect the wiring, connectors and hoses.
Were any problems found?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-6A.
No®Test Complete.
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P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED ÐContinued
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Symptom:
P-0443 EVAP PURGE SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0443 EVAP PURGE SOLENOID CIRCUIT
When Monitored: With the ignition key on and the engine running.
Set Condition: After arming conditions are satisfied: not powering down, not already in
limp-in, time since last solenoid activation > 72 micro seconds. The PCM will set a trouble
code if the actual sate of the solenoid does not match the intended state.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
PROPORTIONAL EVAP PURGE SOLENOID DEFECTIVE
EVAP PURGE SOL CKT WIRING HARNESS INTERMITTENT DEF
EVAP PURGE SOLENOID CKT WIRING HARNESS OBS DEFECT
EVAP PURGE SOLENOID CONTROL CIRCUIT OPEN
EVAP PURGE SOLENOID CONTROL CIRCUIT SHORT TO GND
PROPORTIONAL PURGE SOL CONTROL CKT SHORT TO GROUND
PROPORTIONAL PURGE SOLENOID CONTROL CIRCUIT OPEN
PWM PURGE SENSE CIRCUIT OPEN
PWM PURGE SENSE CIRCUIT SHORT TO GROUND
POWERTRAIN CONTROL MODULE DEFECTIVE
TEST ACTION APPLICABILITY
1 Is the vehicle equipped with a Proportional Purge solenoid? ALL
Ye s®Go To 10
No®Go To 2
2 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?ALL
Ye s®Go To 3
No®Go To 8
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TEST ACTION APPLICABILITY
3 Ignition Off.
Disconnect the Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Key On.
Using a Voltmeter, measure the voltage of the Ignition Switch Output Circuit at
Solenoid Connector.
Is the voltage above 10.0 volts?ALL
Ye s®Go To 4
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off.
Disconnect the Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Key On.
Connect a test light from the Evap Purge Solenoid Control EKT to the Ignition
Switch out CKT.
Using a DRB, actuate the Evap Purge Solenoid.
Does the test light flash on and off?ALL
Ye s®Replace the Evap Purge Solenoid.
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 Ignition Off.
Disconnect Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Evap Purge Solenoid Control Circuit.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 6
No®Repair the open Evap Purge Solenoid Control Circuit.
Perform Powertrain Verification Test VER-5A.
6 Ignition Off.
Disconnect Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Evap Purge Solenoid Control Circuit at Connector
to Ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the Evap Purge Solenoid Control Circuit short to Ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 7
7 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ALL
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
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P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition On, Engine Not Running.
With the DRB, read codes.
With the DRB, actuate the Evap Purge Solenoid.
Wiggle Wiring Harness from the Solenoid to PCM.
Does the Evap Purge Solenoid Control Circuit code return?ALL
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 9
9 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-5A.
No®Go To 10
10 Check the freeze frame data to determine the conditions when code was set.
Attempt duplication of 'freeze frame' conditions for added diagnostics.
If there are no other possible causes remaining there is assumed to be an9intermit-
tent9problem with a Wiring Harness Connector or Wire.
View repair options.ALL
Repair
Visually inspect related Wire Harness Connectors and Harnesses.
Look for broken, bent, pushed out, or corroded terminals and for
chafed, pierced, or partiallly broken wire, respectively. Refer to
any hotlines or technical service bulletins that apply.
11 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?ALL
Ye s®Go To 12
No®Go To 18
12 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the Proportional Purge Solenoid.
Is the resistance 14.2 ohms +/- 1.4?ALL
Ye s®Go To 13
No®Replace the open Proportional Purge Solenoid.
Perform Powertrain Verification Test VER-5A.
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P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
13 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Evap Purge Solenoid Control Circuit at Connector
to ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the Proportional Purge Solenoid Control Circuit short to
ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 14
14 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using and Ohmmeter, measure the Proportional Purge Solenoid Control Circuit
PCM to Solenoid Connector.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 15
No®Repair the open PPS Control Circuit.
Perform Powertrain Verification Test VER-5A.
15 Ignition Off.
Disconnect Proportional Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the battery.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the PWM Purge Sense Circuit to ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the PWM Purge Sense Circuit short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 16
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P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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