2000 CHRYSLER VOYAGER check engine

Symptom:
* CHECKING SECONDARY IGNITION
POSSIBLE CAUSES
SECONDARY IGNITION OUT OF SPECIFICATION
IGNITION COIL DEFECTIVE
SECONDARY IGNITION SYSTEM DEFECTIVE (WATER TEST)
TEST ACTION APPLICABILITY
1 Ignition Off.
Connect a suitable Engine Analyzer to the Engine.
Start Engine.
Allow Engine to idle.
Note: If the Engine will not idle, maintain a constant RPM above idle.
Note: Set the Scope to read, display or parade pattern.
Follow the equipment manufacturer's procedure for pattern analysis.
Is the secondary ignition pattern ok?All
Ye s®Go To 2
No®Repair the indicated component in the Secondary Ignition Sys-
tem.
Perform Powertrain Verification Test VER-2A.
2 Ignition Off
Connect a suitable Engine Analyzer to the engine.
Start the Engine and allow it to idle.
Note: If the engine will not idle, maintain a constant RPM above idle.
Set scope to read display or parade pattern.
Follow the equipment manufacturer's procedure for pattern analysis.
Note: Do not spray the Inductive Pickup.
With a spray bottle, spray the Ignition Cables with water and monitor Ignition
Pattern.
Did the Ignition Pattern change?All
Ye s®Repair the indicated component in the Secondary Ignition Sys-
tem.
Perform Powertrain Verification Test VER-2A.
No®Go To 3
3 Ignition Off
Connect a suitable Engine Analyzer to the engine.
Start the engine and allow it to idle.
Note: If the engine will not idle, maintain a constant RPM above idle.
Note: Set the scope to read display or parade pattern.
Follow the equipment manufacturer's procedure for pattern analysis.
Momentarily remove and reinstall the Spark Plug Wires.
While disconnecting each wire, observe the secondary KV line.
Is the open circuit Secondary voltage at least 25KV?All
Ye s®Test Complete.
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-2A.
252
DRIVEABILITY
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Symptom:
* CHECKING THE ENGINE MECHANICAL SYSTEMS
POSSIBLE CAUSES
CHECKING ENGINE MECHANICAL SYSTEMS
TEST ACTION APPLICABILITY
1 At this point in the diagnostic test procedure, you have determined that all of the
engine electrical systems are operating as designed; therefore, they are not the cause
of the driveability problem.
The following additional items should be checked as possible mechanical causes of
the problem:
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
CAMSHAFT LOBES - check for abnormal wear
CRANK SENSOR PICK-UP - check crankshaft slots for debris/deterioration
ENGINE EXHAUST SYSTEM - must be free of any restrictions
ENGINE PCV SYSTEM - must flow freely
ENGINE DRIVE SPROCKETS - must be properly positioned
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Note: If you came to this test from the oxygen sensor, and the rich or lean
condition is not caused by one of the first items above, replace the power-
train control module and perform TEST VER-2A (Road Test Verification).
Always look for any Technical Service Bulletins that may relate to the problem.
Did you come from an Oxygen Sensor rich or lean condition test?All
Ye s®Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-2A.
No®Test Complete.
253
DRIVEABILITY
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Symptom:
* CHECKING THROTTLE POSITION SENSOR CALIBRATION
POSSIBLE CAUSES
TPS VOLTAGE CHANGE NOT A SMOOTH TRANSITION
TPS VOLTAGE ABOVE 1.5 V WITH THROTTLE CLOSED
THROTTLE CABLE AND BODY BINDING OR RESTRICTED
TPS VOLTAGE BELOW 3.4 V AT WIDE OPEN THROTTLE
TEST ACTION APPLICABILITY
1 Ignition Off
Check the Throttle Cable and Body for binding or restrictions.
Note: Also check Speed Control Cable if equipped.
Is there any binding or restriction?All
Ye s®Repair as necessary.
Perform Verification Test VER-2A.
No®Go To 2
2 Ignition On, Engine Not Running
While slowly opening the Throttle from closed to wide open, monitor the Throttle
Position Sensor voltage at the DRB.
Was the voltage change a smooth transition?All
Ye s®Go To 3
No®Replace Throttle Position Sensor.
Perform Verification Test VER-2A.
3 Ignition On, Engine Not Running
With the DRB, read the Throttle Position Sensor voltage.
Note: Throttle must be fully closed and against the Throttle Stop.
Is the voltage 1.5 V or less with the Throttle closed?All
Ye s®Go To 4
No®Replace Throttle Position Sensor.
Perform Verification Test VER-2A.
4 Was the maximum voltage at least 3.4 volts at wide open Throttle? All
Ye s®Test Complete.
No®Replace Throttle Position Sensor.
Perform Verification Test VER-2A.
254
DRIVEABILITY
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TEST ACTION APPLICABILITY
1 Ignition Off
Note: A misadjusted Brake Switch can cause this code to set.
Does the Brake Switch need to be adjusted?All
Ye s®Adjust Brake Switch as necessary.
No®Go To 2
2 Ignition Off
Disconnect the Speed Control Servo 4-Way Connector.
Note: Check connectors - Clean/repair as necessary.
Note: Ensure the Brake pedal is not depressed during the following steps.
Engine off. Ignition key on and S/C On/Off Switch ON.
Using a Voltmeter, measure the voltage of the S/C Brake Switch Output Circuit at
Speed Control Servo Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 3
No®Go To 10
3 Ignition off.
Disconnect the Speed Control Servo Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of the Gnd Circuit at Servo Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the open Ground Circuit.
Perform Powertrain Verification Test VER-4A.
4 Ignition off
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Note: Ensure the Brake pedal is not depressed during the following steps.
With an ohmmeter, test the resistance from the S/C Power Supply Circuit to the S/C
Vent Solenoid at PCM.
Is the resistance between 35 ohms and 55 ohms?All
Ye s®Go To 5
No®Go To 7
5 Ignition off
Disconnect Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Note: Ensure the Brake Pedal is not depressed during the following steps.
With an ohmmeter, test the resistance from the S/C Power Supply Circuit to the S/C
Vacuum Solenoid Control at PCM.
Is the resistance between 35 ohms and 55 ohms?All
Ye s®Go To 6
No®Go To 7
257
SPEED CONTROL
P-1595 SPEED CONTROL SOLENOID CIRCUITS ÐContinued
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Symptom:
SPEED CONTROL ON/OFF SWITCH
POSSIBLE CAUSES
CLOCKSPRING DEFECTIVE
PCM DEFECTIVE (SPEED CONTROL ON/OFF/SET SWITCH)
SPEED CONTROL GROUND CIRCUIT TO SWITCH OPEN
SPEED CONTROL ON/OFF SWITCH DEFECTIVE
SPEED CONTROL ON/OFF SWITCH SIGNAL CIRCUIT OPEN
SPEED CONTROL ON/OFF SWITCH SIGNAL CIRCUIT SHORT TO GROUND
SPEED CONTROL ON/OFF SWITCH TERMINAL DAMAGED
TEST ACTION APPLICABILITY
1 Ignition on, engine not running.
With the DRBIII, monitor the Speed Control Switch inputs.
While observing the display, press the Speed Control ªONº switch.
Does the DRBIII show S/C on/off ªONº?All
Ye s®Test Complete.
Perform Powertrain Verification Test VER-4A.
No®Go To 2
2 Ignition Off
Disconnect the Speed Control On/Off and Set Switch.
Note: Check connectors - Clean/repair as necessary.
Is any terminal damaged, pushed out or miswired?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-4A.
No®Go To 3
3 Ignition Off
Disconnect the Speed Control On/Off and Set Switch.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the S/C Ground Circuit at the S/C
ON/OFF, SET Switch Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the open Speed Control Ground Circuit to Switch.
Perform Powertrain Verification Test VER-4A.
264
SPEED CONTROL
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TEST ACTION APPLICABILITY
4 Ignition Off
Disconnect the Speed Control On/Off and Set Switch.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire across the S/C Sw Signal Circuit to Ground Circuit.
Ignition On, Engine Not Running.
With the DRBIII, read the S/C Switch voltage.
Does the DRBIII display 0.00 volts?All
Ye s®Replace the S/C ON/OFF and SET Switch.
Perform Powertrain Verification Test VER-4A.
No®Go To 5
5 Ignition Off
Disconnect the Speed Control On/Off and Set Switch.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the S/C Switch Signal at the S/C
ON/OFF, SET Switch Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Speed Control Switch Signal Circuit for a short to
ground.
Perform Powertrain Verification Test VER-4A.
No®Go To 6
6 Ignition Off
Disconnect the Powertrain Control Module.
Disconnect the Clockspring 4±way to I/P Harness.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test the S/C Switch Signal Circuit, Clockspring to PCM.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the open Speed Control Switch Signal Circuit.
Perform Powertrain Verification Test VER-4A.
7 Ignition Off
Disconnect the Speed Control On/Off and set Switch.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure the S/C Switch Signal Ckt, Switch to PCM.
Is the resistance below 5.0 ohms?All
Ye s®Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-4A.
No®Go To 8
8 If there are no potential causes remaining, the Clockspring is assumed to be
defective.
View repair options.All
Repair
Replace the Clockspring.
Perform Powertrain Verification Test VER-4A.
265
SPEED CONTROL
SPEED CONTROL ON/OFF SWITCH ÐContinued
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Symptom:
* CHECKING SPEED CONTROL OPERATION
POSSIBLE CAUSES
BRAKE SWITCH DEFECTIVE
GROUND CIRCUIT OPEN
S/C BRAKE SWITCH OUTPUT CIRCUIT SHORTED TO GROUND
SPEED CONTROL BRAKE SWITCH OUTPUT SUPPLY CKT OPEN
SPEED CONTROL ON/OFF/SET SWITCH DEFECTIVE
SPEED CONTROL POWER SUPPLY CIRCUIT OPEN
SPEED CONTROL POWER SUPPLY CIRCUIT SHORTED/GROUND
SPEED CONTROL SERVO CONNECTOR OBSERVABLE DEFECT
SPEED CONTROL SWITCH DEFECTIVE
CLOCK SPRING DEFECTIVE
SPEED CONTROL SERVO DEFECTIVE
SPEED CONTROL THROTTLE CABLE DEFECTIVE
SPEED CONTROL VACUUM SUPPLY LEAKS OR RESTRICTED
PCM DEFECTIVE (SPEED CONTROL OPERATION)
VACUUM RESERVOIR DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, monitor the Speed Control Switch inputs.
While observing display, press the Speed Control ON/OFF switch.
Does the DRB show S/C ON/OFF switch9ON9?All
Ye s®Go To 2
No®Refer to symptom SPEED CONTROL ON/OFF SWITCH in the
SPEED CONTROL category.
2 Ignition On, Engine Not Running
Press the S/C ON/OFF button to select S/C ªON.º
With the DRB, monitor the Speed Control Switch inputs.
While observing the DRB, press the ACCEL/RESUME/CANCEL and DECEL
switches several times.
Do all of the Switches toggle correctly between pressed and released?All
Ye s®Go To 3
No®Go To 25
266
SPEED CONTROL
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TEST ACTION APPLICABILITY
3 Ignition On, Engine Not Running
Press the S/C ON/OFF button to select S/C ªON.º
With the DRB, monitor the Speed Control Switch inputs.
While observing display, press the Set Switch several times.
Does the DRB show the Set Switch pressed and released?All
Ye s®Go To 4
No®Replace the Speed Control On/Off/Set Switch.
Perform Powertrain Verification Test VER-4A.
4 Ignition On, Engine Not Running
With the DRB, monitor the Speed Control Switch inputs.
While observing display, press the Brake Pedal several times.
Does the DRB show Brake Switch Status change between pressed and released?All
Ye s®Go To 5
No®Refer to symptom SPEED CONTROL BRAKE SWITCH OUT-
PUT in the SPEED CONTROL category.
5 Ignition On, Engine Not Running
With the DRB, monitor the Speed Control Switch inputs.
While observing the display, move the Gear Selector to Drive.
Does the DRB show the Park/Neutral Switch in D/R?All
Ye s®Go To 6
No®Refer to symptom CHECKING PARK/NEUTRAL POS SWITCH
in the SPEED CONTROL category.
6 Ignition Off
Disconnect the Speed Control Servo Connector.
Note: Check connectors - Clean/repair as necessary.
Turn the Ignition on and the S/C on.
Using a Voltmeter measure voltage of the S/C Brake Switch Output Ckt at Servo
Conn.
Is the voltage above 10 volts?All
Ye s®Go To 7
No®Go To 14
7 Ignition Off
Start engine, allow to idle 1 minute.
Turn Engine off, (Ignition on).
With the DRB, actuate the Speed Control Servo Solenoids.
Does the Throttle open and close?All
Ye s®Refer to symptom SPEED CONTROL DENIED MESSAGE in the
SPEED CONTROL category.
No®Go To 8
8 Ignition Off
Inspect the Speed Control Throttle Cable.
Is the Cable disconnected or damaged?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-4A.
No®Go To 9
267
SPEED CONTROL
* CHECKING SPEED CONTROL OPERATION ÐContinued
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