2000 CHRYSLER VOYAGER engine

TEST ACTION APPLICABILITY
32 Ignition Off.
Disconnect the Fuel Pump Harness Connector.
Note; Check connectors - Clean/repair as necessary.
Caution: It is critical that the Fuel Pump Connector has a clean and tight
connection.
Ignition On, Engine Not Running.
Actuate the ASD Fuel System test.
With a Voltmeter, measure the Fuel Pump Relay Output Circuit.
Is the voltage above 10.0 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Go To 33
No®Repair the open Fuel Pump Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
33 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Install a substitute Relay of the same part number for the Fuel Pump Relay.
Attempt to start the Engine.
Does the Engine start?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Ye s®Replace the Fuel Pump Relay.
Perform Powertrain Verification Test VER-1A.
No®Go To 34
34 Ignition Off.
If there are no potential causes remaining, the Fuel Pump is assumed to be defective.
View repair options.ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.3L V6
and/or ENGINE -
3.8L V6
Repair
Replace the Fuel Pump.
Perform Powertrain Verification Test VER-1A.
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* CHECKING THE FUEL SYSTEM ÐContinued
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Symptom:
* CHECKING THE IDLE AIR CONTROL MOTOR
POSSIBLE CAUSES
ENGINE NOT START AND STAY RUNNING
IAC MOTOR DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Hold the Engine Throttle 1/4 of the way down. Attempt to start the Engine.
Does the Engine start and stay running?All
Ye s®Go To 2
No®Refer to Symptom list for further diagnostic tests.
2 Ignition Off
Remove the IAC Motor.
Turn key on.
With the DRB in Actuator Tests, actuate the IAC Stepper Motor.
Observe the Pintle of the IAC Motor.
Is the IAC Motor Pintle moving in and out?All
Ye s®Test Complete.
No®Note: Ensure there are no IAC Motor related Trouble Codes
Before Making the following repair. Replace the IAC motor.
Perform Powertrain Verification Test VER-1A.
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Symptom:
* CHECKING THE SECONDARY IGNITION SYSTEM
POSSIBLE CAUSES
GOOD SPARK AT SPARK PLUG #1
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
COIL SECONDARY CABLE DEFECTIVE
FUSED B(+) CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
IGNITION COIL CONNECTOR OBSERVABLE DEFECT
IGNITION COIL CONNECTOR OBSERVABLE DEFECT
IGNITION COIL DEFECTIVE
IGNITION COIL SECONDARY CABLE #1 DEFECTIVE
IGNITION COIL SECONDARY CABLE #4 DEFECTIVE
SECONDARY IGNITION COMPONENT(S) DEFECTIVE
SPARK PLUG CABLE #1 DEFECTIVE
AUTO SHUTDOWN RELAY DEFECTIVE
AUTO SHUTDOWN RELAY DEFECTIVE
IGNITION COIL DEFECTIVE
IGNITION COIL DEFECTIVE (RESISTANCE OUT OF RANGE)
SPARK PLUG #1 OR #4 DEFECTIVE
GOOD SPARK AT SPARK PLUG #1
GOOD SPARK AT SPARK PLUG #1
TEST ACTION APPLICABILITY
1 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #1.
Connect the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Warning: Ensure that there are no Fuel or Fuel vapors present in or near
the Engine compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 3.0L V6
Ye s®Refer to Symptom list for further diagnostic tests.
No®Go To 2
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TEST ACTION APPLICABILITY
2 Ignition Off.
Remove the Coil Secondary Cable from the Distributor.
Hold the Cable within 1/49of a good Ground.
Caution: Engine Controller damage may occur if more than 1/4(.
While cranking the Engine for 10 seconds, watch for spark.
Note: Consider 1 or 2 sparks as a No Spark condition.
Is there good spark?ENGINE - 3.0L V6
Ye s®Repair the Secondary Ignition: Distributor Cap, Rotor, Cables.
Perform Verification TEST VER-1A
No®Go To 3
3 Ignition Off
Remove the Coil Secondary Cable.
With an Ohmmeter, test the Coil Secondary Cable for resistance.
Is the resistance above 15 Kohms?ENGINE - 3.0L V6
Ye s®Replace the Coil Secondary Cable.
Perform Verification TEST VER-1A
No®Go To 4
4 Ignition Off.
Remove the Distributor Cap.
While cranking the Engine, watch for the Rotor to turn.
Did the Rotor turn when the Engine was cranked?ENGINE - 3.0L V6
Ye s®Go To 5
No®Go To 14
5 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Key On
With the DRB, actuate Ignition Coil.
With a Voltmeter, measure the ASD Output Circuit.
Is the voltage above 10 volts?ENGINE - 3.0L V6
Ye s®Go To 6
No®Go To 11
6 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Using an Ohmmeter, measure each Ignition Coil Primary Circuit for resistance.
Is the resistance below 2.0 ohms for each measurement?ENGINE - 3.0L V6
Ye s®Go To 7
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-1A.
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STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
7 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-1A.
No®Go To 8
8 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, test the resistance of the Ignition Coil Driver Circuit.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 9
No®Repair the open Ignition Coil Driver Circuit.
Perform Powertrain Verification Test VER-1A.
9 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Ignition Coil Driver Circuit at the PCM Conn. to
Ground.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Repair the Ignition Coil Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-1A.
No®Go To 10
10 Ignition off.
If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ENGINE - 3.0L V6
Repair
Replace the Powertrain Control Module.
Perform Powetrain Verification Test VER-1A.
11 Ignition Off.
Disconnect Ignition Coil Connector.
Note: Check connectors - Clean/repair as necesary.
Is any Terminal damaged, pushed out or miswired?ENGINE - 3.0L V6
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
12 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Jumper Wire connect the ASD Relay Output Circuit to Ground at the
Ignition Coil Connector.
With an Ohmmeter mesaure the ASD Output Circuit for resistance to Ground at the
Relay.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 13
No®Repair open ASD Relay Output Circuit.
Perform Powetrain Verification Test VER-1A.
13 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Ignition On, Engine Not Running.
With a Voltmeter, measure the Fused B(+) Circuit cavity B in ASD Relay Connector.
Is the voltage above 10 volts?ENGINE - 3.0L V6
Ye s®Replace the Auto Shutdown Relay.
Perform Powertrain Verification Test VER-1A.
No®Repair open Fused B+.
Perform Verification TEST VER-1A
14 Ignition Off.
Remove the Distributor Cap.
Is the Distributor Rotor loose?ENGINE - 3.0L V6
Ye s®Repair loose Distributor Rotor as necessary.
Perform Verification TEST VER-1A
No®Go To 15
15 If there are no potential causes remaining, the Distributor Drive System is assumed
to be defective.
View repair options.ENGINE - 3.0L V6
Repair
Repair the Distributor Drive System.
Perform Powertrain Verification Test VER-1A.
16 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #1.
Connect the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Warning: Ensure that there are no Fuel or Fuel vapors present in or near
the Engine compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Refer to Symptom list for further diagnostic tests.
No®Go To 17
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
17 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #2.
Connect the other end of the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Ensure that there are no fuel or fuel vapors present in or near the Engine
Compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Go To 18
No®Go To 22
18 Ignition Off.
Disconnect Ignition Coil Secondary Cables #1 and #4 from the Ignition Coil
Terminals.
Note: Check connectors - Clean/repair as necessary.
With Ohmmeter, test the resistance between Coil Terminals #1 and #4.
Is the resistance between 10.9 and 14.7 K ohms?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Go To 19
No®Replace the Ignition Coil.
Perform Powertrain Verification Test VER-1A.
19 Ignition Off.
Disconnect Ignition Coil Secondary Cable #1 from the Ignition Coil Terminal.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #1.
Note: Check connectors - Clean/repair as necessary.
With Ohmmeter, test the resistance of Ignition Coil Secondary Cable #1.
Is the resistance below 15 K ohms?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Go To 20
No®Replace Ignition Coil Secondary Cable #1.
Perform Powertrain Verification Test VER-1A.
20 Ignition Off.
Disconnect Ignition Coil Secondary Cable #4 from the Ignition Coil Terminal.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #4.
Note: Check connectors - Clean/repair as necessary.
With Ohmmeter, test the resistance of Ignition Coil Secondary Cable #4.
Is the resistance below 15 K ohms?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Go To 21
No®Replace Ignition Coil Secondary Cable #4.
Perform Powertrain Verification Test VER-1A.
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
21 Ignition Off.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #1.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #4.
Note: Check connectors - Clean/repair as necessary.
Note: Either Spark Plug #1 or #4 will not produce a good spark.
Remove Spark Plugs #1 and #4.
Inspect and determine which Spark Plug needs replacement.
View repair options.ENGINE - 2.0L
and 2.4L I-4 DOHC
Repair
Replace the Spark Plug that will not produce a spark.
Perform Powertrain Verification Test VER-1A.
22 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect Terminals.
Is any Terminal damaged, pushed out, or miswired?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Repair Terminal(s) for damage, pushout, or miswiring.
Perform Powertrain Verification Test VER-1A.
No®Go To 23
23 Ignition On, Engine Not Running.
With the DRB, actuate Ignition Coil #1.
With a Voltmeter, measure the ASD Relay Output Circuit.
Is the voltage above 10 volts?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Replace Ignition Coil.
Perform Powertrain Verification Test VER-1A.
No®Go To 24
24 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Jumper Wire connect the ASD Relay Output Circuit to Ground at the
Ignition Coil Connector.
With an Ohmmeter, measure the ASD Relay Output Circuit for resistance to ground
at the Relay.
Is the resistance below 5.0 ohms?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Go To 25
No®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
25 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit, cavity B in ASD Relay Connector.
Is the Voltage above 10 volts?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Replace the Auto Shutdown Relay.
Perform Verification Test VER-1A
No®Repair open Fused B(+).
Perform Verification TEST VER-1A
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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