2000 CHRYSLER VOYAGER engine

Symptom:
* CHECKING EGR SYSTEM
POSSIBLE CAUSES
VACUUM LINE TO EGR SOLENOID RESTRICTION OR LEAK
VACUUM NIPPLE AT THROTTLE BODY PLUGGED
EGR VALVE ASSEMBLY DEFECTIVE
EGR VALVE ASSEMBLY DOES NOT HOLD VACUUM
EGR VALVE ASSEMBLY TONE CHANGED
EGR VALVE ASSEMBLY VACUUM <= 3 INCHES
PASSAGES BETWEEN EGR VALVE AND INTAKE CLOSED
TEST ACTION APPLICABILITY
1 Ignition Off
Disconnect the Vacuum Supply Hose at the EGR Solenoid.
Connect a vacuum gauge to the disconnected Vacuum Supply Hose.
Start the Engine.
Was the vacuum above 109at idle?All
Ye s®Go To 2
No®Go To 10
2 Ignition Off
Connect Back Pressure Hose to transducer.
Connect a hand pump to the EGR Valve Nipple.
Start the Engine.
Slowly apply vacuum to the EGR Valve, watch for Engine speed to drop.
Did the Engine speed drop?All
Ye s®Go To 3
No®Go To 6
3 Ignition Off
Adjust a shop air source to 20 PSI and connect to Backpressure Tube at base of EGR
Valve.
While opening and closing the throttle, listen for a tone change.
Did the tone change?All
Ye s®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Connect a hand pump to the EGR Valve Nipple.
Apply 10 inches of vacuum and hold for 30 seconds.
Did the Vacuum hold for 30 seconds?All
Ye s®Go To 5
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
5 Engine Running
Disconnect the EGR Valve Hose from the EGR Valve.
Connect the vacuum gauge to the disconnected EGR Valve Hose.
While watching the gauge, unplug EGR Solenoid Electrical Connector.
Is the Vacuum over 3 inches at this time?All
Ye s®Test Complete.
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
6 Ignition Off
Adjust a shop air source to 20 PSI and connect to Backpressure Tube at base of EGR
Valve.
While opening and closing the throttle, listen for a tone change.
Did the tone change?All
Ye s®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
No®Go To 7
7 Engine Running
Disconnect the EGR Valve Hose from the EGR Valve.
Connect the vacuum gauge to the disconnected EGR Valve Hose.
While watching the gauge, unplug EGR Solenoid Electrical Connector.
Is the Vacuum over 3 inches at this time?All
Ye s®Go To 8
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
8 Ignition Off
Remove the EGR Valve Assembly and inspect passages from Valve to Intake
Manifold.
Were passages open between EGR Valve and intake?All
Ye s®Go To 9
No®Repair the EGR Passages as necessary.
Perform Verification Test VER-2A.
9 Ignition Off
If there are no potential causes remaining, the EGR Valve Assembly is assumed to be
defective.
View repair options.All
Repair
Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
10 Ignition Off
Disconnect the EGR Vacuum Supply Hose at the Intake Manifold.
Connect a vacuum gauge to the Intake Manifold Nipple.
Read the vacuum gauge at idle.
Was the vacuum above 109at idle?All
Ye s®Repair the restriction or leak in the vacuum line to EGR Solenoid.
Perform Verification Test VER-2A.
No®Go To 11
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DRIVEABILITY
* CHECKING EGR SYSTEM ÐContinued
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Symptom:
* CHECKING ENGINE VACUUM
TEST ACTION APPLICABILITY
1 Ignition Off
Connect a Vacuum Gauge to a Vacuum Source on the Engine.
Start the Engine and allow it to idle.
Note: The normal vacuum reading will vary according to the altitude.
While monitoring the vacuum gauge, snap the throttle open a few times. Refer to
vacuum gauge specifications in support material.
Observe the Vacuum Gauge reading at idle.
Is the Vacuum Gauge reading between 13 inches and 22 inches steady?All
Ye s®Test Complete.
No®Refer to symptom * CHECKING THE ENGINE MECHANICAL
SYSTEMS in the DRIVEABILITY category.
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DRIVEABILITY
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Symptom:
* CHECKING EVAPORATIVE EMISSION SYSTEM
POSSIBLE CAUSES
EVAP PURGE SOLENOID DEFECTIVE
EVAP PURGE SOLENOID DEFECTIVE
EVAPORATIVE CANISTER DEFECTIVE
EVAPORATIVE EMISSION VACUUM HOSE OBSERVABLE DEFECT
VACUUM LINE OBSERVABLE DEFECT
VACUUM LINE PLUGGED
VACUUM LINE PLUGGED
TEST PASSED
TEST ACTION APPLICABILITY
1 Ignition Off
Note: Carefully inspect all Vacuum Hoses for proper routing and for
pinched or plugged Hoses from the engine to the PPS to the Gas Tank.
Are all the Vacuum Hoses OK?All
Ye s®Go To 2
No®Repair the Vacuum Hoses as necessary.
Perform Powertrain Verification Test VER-2A.
2 Ignition Off
Start the engine and allow it to reach normal operating temperature 76 deg C (170
deg. F).
Turn ignition off.
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Start the engine.
Note: There should be no flow through the Solenoid from 1 to 2 minutes.
Is the PPS allowing vacuum through the Solenoid within 1 minute?All
Ye s®Go To 3
No®Go To 6
3 Ignition Off
Inspect the line from the PPS to the Canister.
Is the line disconnected, ripped or cut?All
Ye s®Repair the Line and replace the Purge Solenoid.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 Ignition Off
Remove the 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 Evap Purge Solenoid.
Perform Powertrain Verification Test VER-6A.
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TEST ACTION APPLICABILITY
5 If there are no potential causes remaining, the Vacuum Line is assumed to be
defective.
View repair options.All
Repair
Clean out the Line and replace the PPS and Canister.
Perform Powertrain Verification Test VER-2A.
6 Ignition Off
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Note: In the next steps, do not use more that five PSI.
Attempt to blow air through the Vacuum Line that goes to the canister.
Does the Canister and Vacuum Line allow air to pass?All
Ye s®Purge Solenoid and hoses OK. Test passed.
No®Go To 7
7 Ignition Off
Start the engine and allow it to reach normal operating temperature 76 deg C (170
deg F).
Turn ignition off.
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Start the engine.
Note: After 90 seconds, the Purge Solenoid will allow vacuum to cycle
intermittently at a steady rate.
Is the Evap Solenoid allowing vacuum to cycle through intermittently at a steady
rate?All
Ye s®Go To 8
No®Replace the Purge Solenoid.
Perform Powertrain Verification Test VER-6A.
8 Ignition Off
Note: In the next steps, do not use more than five psi.
Disconnect the Purge Vacuum Hose at the Solenoid that goes to the Canister.
Disconnect the Vacuum Line at the Canister that goes to the EVAP Solenoid.
Attempt to blow air through the Vacuum Line that goes to the Canister.
Does the Vacuum Line allow air to pass?All
Ye s®Go To 9
No®Repair or replace the Vacuum Line.
Perform Powertrain Verification Test VER-2A.
9 If there are no potential causes remaining, the Evaporative Canister is assumed to be
defective.
View repair options.All
Repair
Replace the Evaporative Canister.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
* CHECKING EVAPORATIVE EMISSION SYSTEM ÐContinued
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Symptom:
* CHECKING FOR OXYGEN SENSOR SWITCHING
POSSIBLE CAUSES
O2 SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
ENGINE VACUUM ABNORMAL
FUEL DELIVERY SYSTEM DEFECTIVE
O2 SENSOR DEFECTIVE
AIR INLET SYSTEM RESTRICTED
TEST ACTION APPLICABILITY
1 Engine Running
Note: the Engine must be running and at normal operating temperature.
Note: The Downstream O2 Sensor should switch slower than the Upstream
O2 Sensor.
With the DRB, read the O2 Sensor voltages for 10 seconds or more.
Are the O2 Sensor voltages switching normally?All
Ye s®Test Complete.
No®Go To 2
2 Engine Running
Note: The Engine must be running and at normal operating temperature.
Note: The Downstream O2 Sensor should switch slower than the Upstream
O2 Sensor.
With the DRB, read the O2 Sensor voltages for 10 seconds or more.
Is the Upstream O2 Sensor locked9LEAN9?All
Ye s®Go To 3
No®Go To 9
3 Ignition On, Engine Not Running
With the DRB, read the O2 Sensor Signal voltages.
Is the voltage below 0.10 volts for the Upstream or Downstream O2 Sensor?All
Ye s®Go To 4
No®Go To 7
4 Engine Running
Allow the Engine to idle.
Inspect the Engine for any abnormal vacuum conditions.
Are there any abnormal vacuum conditions?All
Ye s®Repair abnormal Engine Vacuum condition as required.
Perform Powertrain Verification Test VER-2A.
No®Go To 5
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TEST ACTION APPLICABILITY
5 Ignition Off
Disconnect the Upstream or Downstream O2 Sensor Connector that the voltage is
below 0.10 volts.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance between the O2 Sensor Signal Circuit
and a good ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the O2 Sensor Signal Circuit for a short to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 If there are no potential causes remaining, the Upstream or Downstream O2 Sensor
is assumed to be defective.
View repair options.All
Repair
Replace the Upstream or Downstream O2 Sensor that was below
0.10 volts.
Perform Powertrain Verification Test VER-2A.
7 Engine Running
Allow the Engine to idle.
Inspect the Engine for any abnormal vacuum conditions.
Are there any abnormal vacuum conditions?All
Ye s®Repair abnormal Engine Vacuum condition as required.
Perform Powertrain Verification Test VER-2A.
No®Go To 8
8 Engine Running
With the DRB, reset the Adaptive Fuel Memory.
Note: The engine must be running and at normal operating temperature.
Note: The Downstream O2 Sensor should switch slower than the Upstream
O2 Sensor.
With the DRB, read the O2 Sensor voltages for 10 seconds or more.
Are the O2 Sensor voltages switching normally?All
Ye s®Test Complete.
No®Refer to symptom * CHECKING THE ENGINE MECHANICAL
SYSTEMS in the DRIVEABILITY category.
9 Ignition Off
Install a Fuel Pressure Gauge to the Fuel Line. Use special tools if necessary.
Turn ignition on.
With the DRB, actuate the ASD Fuel System Test.
Allow Fuel Pressure to stabilize.
With the DRB, stop Fuel System Test. Monitor the Pressure Gauge for 1 minute.
Is the Fuel Pressure below 10 psi?All
Ye s®If Fuel Pump and Lines are OK, replace leaking Injector(s) as
necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 10
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DRIVEABILITY
* CHECKING FOR OXYGEN SENSOR SWITCHING ÐContinued
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TEST ACTION APPLICABILITY
10 Ignition Off
Inspect the Air Filter and Inlet Ducts for restriction(s).
Were there any restrictions?All
Ye s®Repair or replace the Air Inlet System as necessary.
Perform Powertrain Verification Test VER-2A.
No®Refer to symptom * CHECKING THE ENGINE MECHANICAL
SYSTEMS in the DRIVEABILITY category.
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DRIVEABILITY
* CHECKING FOR OXYGEN SENSOR SWITCHING ÐContinued
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