2000 CHRYSLER VOYAGER fuel pressure

CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
HESITATION/
SAG/
STUMBLECHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING ENGINE VAC-
UUM
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING O2S HEATER
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING ENGINE ME-
CHANICAL SYSTEMS
CHECKING EVAP EMISSION
SYSTEM
CHECKING EGR SYSTEM
CHECKING IAT SENSOR
CHECKING PNP SWITCH
SURGE CHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATIONCHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EVAP EMISSION
SYSTEM
LACK OF
POWER/
SLUGGISHCHECKING THE 5-VOLT
SUPPLY CIRCUIT
CHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EGR SYSTEM
SPARK
KNOCK/
DETONATIONCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
9
GENERAL INFORMATION
ProCarManuals.com

CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EVAP EMISSION
SYSTEM
CUTS OUT/
MISSESCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING EGR SYSTEM
BACKFIRE/
POPBACKCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING THE FUEL
PRESSURE
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING EGR SYSTEM
RUNS
ROUGH/
UNSTABLE/
ERRATIC
IDLECHECKING SECONDARY
IGNITION SYSTEMCHECKING PCM POWER
AND GND CKT
CHECKING ENGINE VAC-
UUM
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING O2S HEATER
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING ENGINE ME-
CHANICAL SYSTEMS
CHECKING EVAP EMISSION
SYSTEM
CHECKING EGR SYSTEM
CHECKING IAT SENSOR
CHECKING PNP SWITCH
POOR FUEL
ECONOMYCHECKING SECONDARY
IGNITION SYSTEM
CHECKING PCM POWER
AND GND CKT
CHECKING ENGING VAC-
UUM
CHECKING THE FUEL
PRESSURE
CHECKING COOLANT SEN-
SOR CALIBRATION
CHECKING THROTTLE PO-
SITION SENSOR CALIBRA-
TION
CHECKING MAP SENSOR
CALIBRATION
CHECKING THE MINIMUM
IDLE AIR FLOW
10
GENERAL INFORMATION
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4.3.3 ELECTRONIC PINION FACTOR
WARNING
The pinion factor must be set for all new trans-
mission control modules. If the pinion factor is not
set or if it is set incorrectly, any speed-related
accessories will not operate or will operate inaccu-
rately. This includes the speedometer, speed con-
trol, rolling door locks, and other devices that are
operated by the powertrain and body control mod-
ules. For instructions on setting the pinion factor,
see the appropriate transmission diagnostic man-
ual or the service manual.
5.0 RECOMMENDED TOOLS
AND EQUIPMENT
DRBIIIt(diagnostic readout box) scan tool
fuel pressure adapter (C-6631) or #6539
fuel pressure kit (C-4799-B) or #5069
fuel release hose (C-4799-1)
MinAir flow fitting #6457
jumper wires
ohmmeter
oscilloscope
vacuum gauge
voltmeter
12 volt test light minimum 25 ohms resistance
with probe #8382
CAUTION: A 12 VOLT TEST LIGHT SHOULD
NOT BE USED FOR THE FOLLOWING
CIRCUITS, DAMAGE TO THE POWERTRAIN
CONTROLLER WILL OCCUR.
²5 Volt Supply
²8 Volt Supply
²J1850 PCI Bus
²CCD Bus
²CKP Sensor Signal
²CMP Sensor Signal
²Vehicle Speed Sensor Signal
²O2 Sensor Signal
6.0 GLOSSARY OF TERMS
ABSantilock brake system
backfire,
popbackfuel ignites in either the intake or
the exhaust system
CKPcrank position sensor
CMPcamshaft position sensor
cuts out,
missesa steady pulsation or the inability of
the engine to maintain a consistent
rpmDLCdata link connector (previously
called ªengine diagnostic connectorº)
detona-
tion,
spark
knocka mild to severe ping, especially un-
der loaded engine conditions
ECTengine coolant temperature sensor
EGRexhaust gas recirculation valve and
system
genera-
torpreviously called ªalternatorº
hard
startThe engine takes longer than usual
to start, even though it is able to
crank normally.
hesita-
tion, sag,
stumble
There is a momentary lack of response
when the throttle is opened.
This can
occur at all vehicle speeds. If it is se-
vere enough, the engine may stall.
IATintake air temperature sensor
IACidle air control valve
JTECCombined engine and transmission
control module
lack of
power,
sluggish
The engine has less than expected
power, with little or no increase in vehi-
cle speed when the throttle is opened.
LDPLeak Detection Pump
MAPmanifold absolute pressure sensor
MILmalfunction indicator lamp
MTVmanifold tuning valve
O2Soxygen sensor
PCIProgrammable Communication In-
terface
PCMpowertrain control module
PCMpowertrain control module
PCVpositive crankcase ventilation
PEPPeripheral Expansion Port
poor fuel
economyThere is significantly less fuel mile-
age than other vehicles of the same
design and configuration
rough,
unstable,
or er-
ratic idle
stallingThe engine runs unevenly at idle
and causes the engine to shake if it
is severe enough. The engine idle
rpm may vary (called ªhuntingº).
This condition may cause stalling if
it is severe enough.
SKIMSentry Key Immobilizer Module
SKISSentry Key Immobilizer System
start and
stallThe engine starts but immediately
dies.
13
GENERAL INFORMATION
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Symptom:
P-0171±1/1 FUEL SYSTEM LEAN
When Monitored and Set Condition:
P-0171±1/1 FUEL SYSTEM LEAN
When Monitored: With the engine running in closed loop mode, the ambient, battery
temperature above Ð5 deg. C (20 deg. F) and altitude below 8000 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
a certain percentage is exceeded for two trips, a freeze frame is stored, the MIL illuminates
and a trouble code is stored.
POSSIBLE CAUSES
FUEL PUMP MODULE DEFECTIVE
TPS VOLTAGE CHANGE NOT SMOOTH
TPS VOLTAGE <0.92V
FUEL INLET STRAINER PLUGGED
ECT SENSOR DEFECTIVE (OUT OF CALIBRATION)
MAP SENSOR DEFECTIVE (OUT OF CALIBRATION)
ENGINE MECHANICAL PROBLEM
FUEL FILTER/PRESSURE REGULATOR DEFECTIVE (HIGH)
FUEL FILTER/PRESSURE REGULATOR DEFECTIVE (LOW)
FUEL PUMP CAPACITY (VOLUME) OUT OF SPECS
TEST ACTION APPLICABILITY
1 Turn ignition on.
With the DRB, read the DTC's.
Is the Global Good Trip Counter displayed and equal to zero for P0171?All
Ye s®Go To 2
No®Go To 13
2 Ignition On, Engine Not Running
With the DRB, read the TPS voltage.
While monitoring the DRB, slowly open and close the Throttle.
Is the voltage change smooth?All
Ye s®Go To 3
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
75
DRIVEABILITY
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TEST ACTION APPLICABILITY
7 Turn ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Remove the pressure test port cap at the fuel rail test port. Connect a fuel pressure
gauge to the test port pressure fitting on the fuel rail.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/- 5 psi
Choose a conclusion that best matches your fuel pressure reading.All
Below Specification
Go To 8
Within Specification
Go To 11
Above Specification
Replace the fuel filter pressure regulator.
Caution: Stop ALL Actuations.
8 Turn ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Raise vehicle on hoist,and disconnect the fuel pressure line at the fuel pump module.
Install speial 5/169fuel line adapter tool #6539 between disconnected fuel line and
the fuel pump module.
Attach a fuel pressure test gauge to the88T'' fitting on tool #6539.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/- 5 psi.
Is the fuel pressure within specification now?ALL
Ye s®Repair the restriction in the chassis fuel supply line between the
fuel tank and fuel rail.
No®Go to 9
Caution: Stop ALL Actuations.
9Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?All
Ye s®Replace the Fuel Inlet Strainer.
No®Go To 10
10 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.All
Repair
Replace the Fuel Pump Module
77
DRIVEABILITY
P-0171±1/1 FUEL SYSTEM LEAN ÐContinued
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TEST ACTION APPLICABILITY
11 Check for any of the following conditions/mechanical problems.
ENGINE VACUUM Ð must be at least 13 inches in neutral
ENGINE VALVE TIMING Ð must be within specifications
ENGINE COMPRESSION Ð must be within specifications
ENGINE EXHAUST SYSTEM Ð must be free of any restrictions or leaks
ENGINE PVC SYSTEM Ð must flow freely
TORQUE CONVERTER STALL SPEED Ð must be within specifications
POWER BRAKE BOOSTER Ð no internal vacuum leaks
FUEL- must be free of contamination
FUEL INJECTOR Ð plugged or restricted injector; control wire not connected to
correct injector.
Are there any engine mechanical problems?All
Ye s®Repair as necessary.
Perform FUEL SYSTEM/MISFIRE MONITOR VERIFICATION
TEST
No®Go To 12
12 Turn ignition off.
Warning: The fuel system is under constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Disconnect the fuel supply line at the fuel rail.
Connect fuel line adapter #6539(5/169) or #6631 (3/89) to the disconnected fuel supply
line. Insert the other end of the adapter into a graduated container.
Caution: Do not operate the fuel pump for more than 7 seconds in the next
step. Fuel pump module reservoir may run empty and damage to the fuel
pump may result.
Specification: A good fuel pump will deliver at least 1/4 liter of fuel in 7
seconds.
With the DRB, actuate the ASD Fuel System test for 7 seconds.
Is the fuel pump capacity within specification?All
Ye s®Test Complete.
No®Check for a kinked/damaged fuel supply line between the fuel
tank and fuel rail. If OK, replace the fuel filter/pressure regulator.
Caution: Stop ALL Actuations.
13 The conditions required to set the DTC are no longer present.
With the DRB read and record the freeze frame data and the ªFuel System Similar
Conditions Windowº data.
Utilize the data and try to duplicate the operating conditions at which the DTC was
set. Pay particular attention to the ECT and RPM for added diagnostics.
Note: Refer to any TSB's that may apply to the symptom.
Test Complete
Repair
Test Complete.
78
DRIVEABILITY
P-0171±1/1 FUEL SYSTEM LEAN ÐContinued
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Symptom
P0172 -1/1 FUEL SYSTEM RICH
When Monitored and Set Condition:
P0172 -1/1 FUEL SYSTEM RICH
When Monitored: With the engine in closed loop mode, the ambient/battery temperature
above þ5 deg. C (20 deg. F) and altitude below 8000 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
the result is below a certain value for two trips, a freeze frame is stored, the MIL
illuminates and a trouble code is stored.
POSSIBLE CAUSES
FUEL PUMP MODULE DEFECTIVE
TPS VOLTAGE CHANGE NOT SMOOTH
TPS VOLTAGE <0.92V
FUEL INLET STRAINER PLUGGED
ECT SENSOR DEFECTIVE (OUT OF CALIBRATION)
MAP SENSOR DEFECTIVE (OUT OF CALIBRATION)
ENGINE MECHANICAL PROBLEM
FUEL FILTER/PRESSURE REGULATOR DEFECTIVE (HIGH)
FUEL FILTER/PRESSURE REGULATOR DEFECTIVE (LOW)
TEST ACTION APPLICABILITY
1 Turn ignition on.
With the DRB, read the DTC's.
Is the DTC Specific Good Trip Counter displayed and equal to zero?All
Ye s®Go To 2
No®Go To 14
2 Ignition On, Engine Not Running
With the DRB, read the TPS voltage.
While monitoring the DRB, slowly open and close the Throttle.
Is the voltage change smooth?All
Ye s®Go To 3
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
79
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TEST ACTION APPLICABILITY
8 Turn ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Remove the pressure test port cap at the fuel rail test port. Connect a fuel pressure
gauge to the test port pressure fitting on the fuel rail.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/þ 5 psi.
Choose a conclusion that best matches your fuel pressure reading.All
Below Specification
Go To 9
Within Specification
Go To 13
Above Specification
Replace the fuel filter/pressure regulator.
Caution: Stop ALL Actuations.
9 Check for any of the following conditions/mechanical problems.
ENGINE VACUUM Ð must be at least 13 inches in neutral
ENGINE VALVE TIMING Ð must be within specifications
ENGINE COMPRESSION Ð must be within specifications
ENGINE EXHAUST SYSTEM Ð must be free of any restrictions or leaks.
ENGINE PVC SYSTEM Ð must flow freely
TORQUE CONVERTER STALL SPEED Ð must be within specifications
POWER BRAKE BOOSTER Ð no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR Ð plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?All
Ye s®Repair as necessary.
Perform FUEL SYSTEM/MISFIRE MONITOR VERIFICATION
TEST
No®Go To 10
10 Turn ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/169fuel line adapter tool #6539 between disconnected fuel line and
the fuel pump module.
Attach a fuel pressure test gauge to the ªT'' fitting on tool #6539.
Ignition on. With the DRB, actuate the ASD Fuel System test and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 49.2 psi +/- 5 psi.
Is the fuel pressure within specification now?All
Ye s®Repair the restriction in the chassis fuel supply line between the
fuel tank and fuel rail.
No®Go to 11
Caution: Stop ALL Actuations.
81
P0172 -1/1 FUEL SYSTEM RICH ÐContinued
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