2000 CHRYSLER VOYAGER brake

TEST ACTION APPLICABILITY
8 Ignition Off
Inspect the Chassis Fuel Supply Line to engine for a kink or restriction.
Is the Line kinked or restricted?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 9
9 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is the Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Go To 10
10 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Test Complete.
No®Release the Fuel Pressure. Replace the Fuel Pump and Regulator
Assembly.
Perform Powertrain Verification Test VER-2A.
11 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Relieve the Fuel Pressure.
Tee-in Fuel Pressure Gauge into the Fuel Supply Hose using Tool #6433.
Turn ignition on.
With the DRB, actuate the ASD Fuel System test.
Is the Fuel Pressure between 43 and 53 psi?ENGINE - 3.0L V6
Ye s®Go To 12
No®Go To 15
12 Ignition Off
Note: Make sure the Gear Lever is in neutral, and the Park Brakes engaged.
Start the engine.
Monitor the Fuel Pressure Gauge in the next step.
While monitoring the pressure, momentarily snap Throttle wide open raising RPM to
above 3000.
Did the fuel pressure drop below 35 psi at all?All
Ye s®Go To 13
No®Test Complete.
239
DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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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 List:
P-1595 SPEED CONTROL SOLENOID CIRCUITS
P-1683 SPEED CONTROL POWER RELAY OR S/C 12V DRIVER
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P-1595 SPEED CONTROL SOLE-
NOID CIRCUITS.
When Monitored and Set Condition:
P-1595 SPEED CONTROL SOLENOID CIRCUITS
When Monitored: Speed control on, vehicle speed > 25 mph, RPM < 5440, brake not
applied. For an automatic transmission, in drive mode. For a manual transmission, the
clutch not depressed.
Set Condition: The powertrain control module (PCM) actuates the vacuum and vent
solenoid but they do not respond.
P-1683 SPEED CONTROL POWER RELAY OR S/C 12V DRIVER
When Monitored: Speed control on, vehicle speed > 25 mph, RPM < 5440, brake not
applied. For an automatic transmission, in drive mode. For a manual transmission, the
clutch not depressed.
Set Condition: The powertrain control module (PCM) actuates the vacuum and vent
solenoids but they do not respond.
POSSIBLE CAUSES
S/C BRAKE SWITCH OUTPUT CIRCUIT OPEN
S/C BRAKE SWITCH OUTPUT CIRCUIT SHORTED TO GROUND
S/C VACUUM SOLENOID CONTROL CIRCUIT OPEN
S/C VENT SOLENOID CONTROL CIRCUIT OPEN
SPEED CONTROL POWER SUPPLY CIRCUIT OPEN
SPEED CONTROL SERVO GROUND CIRCUIT OPEN
BRAKE SWITCH DEFECTIVE
SPEED CONTROL SERVO DEFECTIVE
PCM DEFECTIVE (SC SOLENOID CIRCUIT)
PCM DEFECTIVE (SPEED CONTROL P/S CIRCUIT)
BRAKE SWITCH NEEDS TO BE ADJUSTED
256
SPEED CONTROL
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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
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SPEED CONTROL
P-1595 SPEED CONTROL SOLENOID CIRCUITS ÐContinued
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TEST ACTION APPLICABILITY
6 Ignition off.
If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.All
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-4A.
7 Ignition off.
Disconnect the Powertrain Control Module.
Disconnect Speed Control Servo 4-way Connector.
Note: Check connectors - Clean/repair as necessary.
With an ohmmeter, test the resistance of the SC Vacuum Solenoid Control Circuit
from the PCM to the Servo Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair the open Speed Control Vacuum Solenoid Control Circuit.
Perform Powertrain Verification Test VER-4A.
8 Ignition off.
Disconnect the PCM.
Disconnect Speed Control Servo 4-way Connector.
Note: Check connectors - Clean/repair as necessary.
With an ohmmeter, test the resistance of the S/C Vent Solenoid Control Circuit from
the PCM to the Servo Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 9
No®Repair the open Speed Control Vent Solenoid Control Circuit.
Perform Powertrain Verification Test VER-4A.
9 Ignition off.
If there are no potential causes remaining, the Speed Control Servo is assumed to be
defective.
View repair options.All
Repair
Replace the Speed Control Servo.
Perform Powertrain Verification Test VER-4A.
10 Ignition off.
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
Key and S/C On.
Using a Voltmeter, probe Speed Control Power Supply Ckt at the Brake Sw
Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 11
No®Go To 14
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SPEED CONTROL
P-1595 SPEED CONTROL SOLENOID CIRCUITS ÐContinued
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TEST ACTION APPLICABILITY
11 Ignition Off
Disconnect the Speed Control Servo 4-Way Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the S/C Brake Switch Output Circuit
from the Servo Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair shorted S/C Brake Switch Output Circuit.
Perform Verification TEST VER-4A
No®Go To 12
12 Ignition Off
Disconnect the Speed Control Servo 4-Way Connector.
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the resistance of the S/C Brake Switch Output Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 13
No®Repair the open S/C Brake Switch Output.
Perform Powertrain Verification Test VER-4A
13 If there are no potential causes remaining, the Brake Switch is assumed to be
defective.
View repair options.All
Repair
Replace the Brake Switch.
Perform Powertrain Verification Test VER-4A.
14 Ignition Off
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the resistance of the S/C Brake Switch Output Circuit
from the Brake Switch Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair shorted S/C Brake Switch Output Circuit.
Perform Verification TEST VER-4A
No®Go To 15
15 Ignition off.
Disconnect the Powertrain Control Module.
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
With an ohmmeter, test resistance of the Speed Control Power Supply Ckt.
Is the resistance below 5.0 ohms?All
Ye s®Go To 16
No®Repair the open Speed Control Power Supply Circuit.
Perform Powertrain Verification Test VER-4A.
259
SPEED CONTROL
P-1595 SPEED CONTROL SOLENOID CIRCUITS ÐContinued
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Symptom:
SPEED CONTROL BRAKE SWITCH OUTPUT
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
PCM CONNECTOR OBSERVABLE DEFECT
BRAKE SWITCH DEFECTIVE
BRAKE SWITCH SENSE CIRCUIT OPEN
BRAKE SWITCH SENSE CIRCUIT SHORTED TO GROUND
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
Key on.
Using a Voltmeter, measure the voltage of the Brake Switch Sense at the Brake
Switch Connector.
Is the voltage above 10 volts?All
Ye s®Go To 2
No®Go To 3
2 Ignition Off
Disconnect the Brake Switch Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper between the Brake Switch Sense and Brake Switch Ground CKT.
With the DRB, read the Brake Switch input status.
Does the DRB show Brake SW9Released9?All
Ye s®Replace the Brake Switch.
Perform Powertrain Verification Test VER-4A
No®Repair the open Brake Switch Ground CKT.
Perform Powertrain Verification Test VER-4A.
3 Ignition Off
Disconnect the PCM.
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 4
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SPEED CONTROL
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TEST ACTION APPLICABILITY
4 Ignition Off
Disconnect the Brake Switch Connector.
Disconnect the PCM Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Brake Switch Sense Circuit from Brake Switch to
PCM.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open Brake Switch Sense Circuit.
Perform Powertrain Verification Test VER-4A.
5 Ignition Off
Disconnect the Brake Switch Connector.
Disconnect the PCM.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Brake Switch Sense Circuit from the
Brake Switch Connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Brake Switch Sense Circuit, shorted to ground.
Perform Powertrain Verification Test VER-4A.
No®Go To 6
6 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-4A.
262
SPEED CONTROL
SPEED CONTROL BRAKE SWITCH OUTPUT ÐContinued
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