2000 CHRYSLER VOYAGER Diagnostic Manual

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
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser 's guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIItfunctions.
3.5 DRB ERROR MESSAGES AND BLANK
SCREEN
Under normal operation, the DRBIIItwill dis-
play one of only two error messages:
± User-Requested WARM Boot or User-
Requested COLD Boot.
This is a sample of such an error message display:
ver: 2.14
date: 26 Jul93
file: key_itf.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
3.5.1 DRB IIITDOES NOT POWER UP
If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage (data link
connector cavity 16). A minimum of 11 volts is
required to adequately power the DRBIIIt.
If all connections are proper between the
DRBIIItand vehicle or other devices, and the
vehicle battery is fully charged, an inoperative
DRBIIItmay be the result of a faulty cable or
vehicle wiring. For a blank screen, refer to the
appropriate body diagnostics manual.
3.5.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially impor-
tant to block the wheels on front-wheel drive vehicles;
the parking brake does not hold the drive wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing a powertrain system problem,
it is important to follow approved procedures where
11
GENERAL INFORMATION
ProCarManuals.com

applicable. These procedures can be found in ser-
vice manual procedures. Following these proce-
dures is very important to the safety of individuals
performing diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced in assembly only. Attempt-
ing to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRB MULTIMETER IS DANGEROUS. IT CAN
EXPOSE YOU TO SERIOUS INJURY.
CAREFULLY READ AND UNDERSTAND THE
CAUTIONS AND THE SPECIFICATION
LIMITS.
Follow the vehicle manufacturer 's service specifi-
cations at all times.
²Do not use the DRBIIItif it has been damaged.
²Do not use the test leads if the insulation is
damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test
leads, tips or the circuit being tested.
²Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
²Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 -1.12 megohms
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100ÉF
-50 - 600ÉC
* Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
²Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
²Use caution when measuring voltage above 25v
DC or 25v AC.
²The circuit being tested must be protected by a
10A fuse or circuit breaker.
²Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeding 10A.
²When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before accepting a zero reading.
²When measuring current, connect the meter in
series with the load.
²Disconnect the live test lead before disconnecting
the common test lead.
²When using the meter function, keep the DRB
away from spark plug or coil wires to avoid
measuring error from outside interference.
4.3 WARNINGS AND CAUTIONS
4.3.1 ROAD TEST WARNINGS
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL
COMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRB SCREEN WHILE IN MOTION.
DO NOT HANG THE DRB FROM THE REAR
VIEW MIRROR OR OPERATE IT YOURSELF.
HAVE AN ASSISTANT AVAILABLE TO
OPERATE THE DRB.
4.3.2 VEHICLE DAMAGE CAUTIONS
Before disconnecting any control module, make
sure the ignition is ªoffº. Failure to do so could
damage the module.
When testing voltage or continuity at any control
module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the
insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second code could be set, making diagnosis of the
original problem more difficult.
12
GENERAL INFORMATION
ProCarManuals.com

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
ProCarManuals.com

surgeengine rpm fluctuation without cor-
responding change in throttle posi-
tion sensor
TPSthrottle position sensorTRStransmission range sensor
VSSvehicle speed sensor/signal
14
GENERAL INFORMATION
ProCarManuals.com

7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
15
ProCarManuals.com

Symptom:
P-0622 GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored and Set Condition:
P-0622 GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored: With the ignition key on and the engine not running.
Set Condition: This trouble code sets when the PCM tries to regulate the generator field
with no result during monitoring.
POSSIBLE CAUSES
GENERATOR FIELD RESISTANCE > = 5.0 OHMS
ASD WIRING HARNESS INTERMITTENT DEFECT
ASD WIRING HARNESS OBSERVABLE DEFECT
GENERATOR FIELD DRIVE CIRCUIT SHORT TO GROUND
GENERATOR FIELD DRIVER CIRCUIT OPEN
PCM DEFECTIVE (GENERATOR)
ASD RELAY OUTPUT CIRCUIT OPEN
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running.
With the DRB, actuate the Generator Field Driver Circuit.
Backprobe the ASD Relay Output Circuit at the back of the Generator.
Is the voltage above 10.0 volts?All
Ye s®Go To 2
No®Repair the open ASD Relay Output Circuit, Generator to Harness
Splice.
2 Engine Running
With the DRB, actuate the Generator Field Driver Circuit.
Backprobe the Generator Field Driver Circuit at the back of the Generator.
Does the voltage shift from low to high?All
Ye s®Go To 3
No®Go To 5
3 Ignition On, Engine Not Running.
With the DRB, actuate the Generator Field Driver Circuit.
With the DRB, read codes.
Wiggle Wiring Harness from the Generator to PCM.
Does the Generator Field Driver Circuit code return?All
Ye s®Repair as necessary where wiggling caused problem to appear.
Perform Powertrain Verification Test VER-3A.
No®Go To 4
16
CHARGING
ProCarManuals.com

TEST ACTION APPLICABILITY
4 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-3A.
No®Test Complete.
5 Ignition Off
Disconnect the PCM.
Disconnect the Generator Field Harness Connector at back of the Generator.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test resistance across the Generator Field Terminals.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Generator as necessary.
Perform Powertrain Verification Test VER-3A.
6 Ignition Off
Disconnect the PCM.
Disconnect the Generator Field Harness Connector at back of the Generator.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of Generator Field Driver Circuit from
the at Generator Harness Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Generator Field Driver Circuit short to ground.
Perform Powertrain Verification Test VER-3A.
No®Go To 7
7 Ignition Off
Disconnect the PCM.
Disconnect the Generator Field Harness Connector at back of the Generator.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test the resistance of the Generator Field Driver Circuit
Generator Connector to PCM Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair open Generator Field Driver Circuit Generator to PCM.
Perform Powertrain Verification Test VER-3A.
8 Ignition Off
If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-3A.
17
CHARGING
P-0622 GENERATOR FIELD NOT SWITCHING PROPERLY ÐContinued
ProCarManuals.com

Symptom List:
P-1492 BATTERY TEMP SENSOR VOLTAGE TOO HIGH
P-1493 BATTERY TEMP SENSOR VOLTAGE TOO LOW
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P-1492 BATTERY TEMP SENSOR
VOLTAGE TOO HIGH.
When Monitored and Set Condition:
P-1492 BATTERY TEMP SENSOR VOLTAGE TOO HIGH
When Monitored: With the ignition key on.
Set Condition: The PCM senses the voltage from the BTS to be either below 0.1 volts or
above 4.9 volts for 3 seconds.
P-1493 BATTERY TEMP SENSOR VOLTAGE TOO LOW
When Monitored: With the ignition key on.
Set Condition: The PCM senses the voltage from the BTS to be either below 0.1 volts or
above 4.9 volts for 3 seconds.
POSSIBLE CAUSES
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the Trouble Codes.
Does the DRB show9Battery Temperature Sensor Voltage9with a run count of zero?All
Ye s®Replace the PCM.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
18
CHARGING
ProCarManuals.com