2000 CHRYSLER VOYAGER key

Symptom:
P-0205 INJECTOR #5 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0205 INJECTOR #5 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
POSSIBLE CAUSES
ASD RELAY OUTPUT CIRCUIT OPEN
INJECTOR #5 DEFECTIVE
INJECTOR #5 DRIVER CIRCUIT OPEN
INJECTOR #5 DRIVER CIRCUIT SHORT TO GROUND
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Start engine, let idle for at least 20 seconds.
Key on, engine off.
With the DRB, read Trouble Codes.
Is the Global Good Trip counter displayed and equal to zero?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Disconnect Injector #5 Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #5.
Is the resistance between 10.0 and 16.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 3
No®Replace the Fuel Injector.
Perform Powertrain Verification Test VER-5A.
3 Ignition Off
Disconnect Injector #5 Connector.
Note: Check connectors - Clean/repair as necessary.
Turn the ignition on.
With the DRB, actuate the Auto Shutdown Relay.
Using a Voltmeter, measure the ASD Relay Output voltage.
Does the voltage cycle high and low?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 4
No®Repair the open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-5A.
95
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Symptom:
P-0206 INJECTOR #6 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0206 INJECTOR #6 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
POSSIBLE CAUSES
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
INJECTOR #6 DEFECTIVE (RESISTANCE OUT OF RANGE)
INJECTOR #6 DRIVER CIRCUIT OPEN
INJECTOR #6 DRIVER CIRCUIT SHORTED TO GROUND
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Ignition Off
Start engine, let idle for at least 20 seconds.
Key on, engine off.
With the DRB, read Trouble Codes.
Is the Global Good Trip counter displayed and equal to zero?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Note: It may be necessary to remove the Intake Plenum in the following
step.
Disconnect the Injector #6 Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #6.
Is the resistance between 10.0 and 16.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 3
No®Replace the Fuel Injector.
Perform Powertrain Verification Test VER-5A.
97
DRIVEABILITY
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Symptom:
P-0353 IGNITION COIL #3 PRIMARY CIRCUIT
When Monitored and Set Condition:
P-0353 IGNITION COIL #3 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, and none of the coils in dwell when checked.
Set Condition: Peak current is not achieved with 2.5ms of dwell. It takes 3 seconds during
cranking or up to 6 seconds while running to set.
POSSIBLE CAUSES
ASD OUTPUT CIRCUIT OPEN
IGNITION COIL CONNECTOR #3 TERMINAL OBSERVABLE DEF
IGNITION COIL #3 DRIVER CIRCUIT OPEN
IGNITION COIL #3 DRIVER CIRCUIT SHORTED TO GROUND
IGNITION COIL CIRCUIT WIRING HARNESS INTER DEFECT
IGNITION COIL CIRCUIT WIRING HARNESS OBS DEFECT
IGNITION COIL #3 RESISTANCE NOT ABOVE 2.0 OHMS
PCM DEFECTIVE (IGN COIL #3)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 2
No®Go To 8
2 Ignition Off
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Key on.
With the DRB, actuate Ignition Coil #3.
With a Voltmeter, probe the ASD Output Circuit.
Is the voltage above 10.0 volts?Engine Ð 3.3L V6
and/or 3.8L V6
and/or Engine Ð
3.3L V6 FFV
Ye s®Go To 3
No®Repair the open ASD Output Circuit.
Perform Powertrain Verification Test VER-2A.
128
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Symptom:
P-0403 EGR SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0403 EGR SOLENOID CIRCUIT
When Monitored: With the ignition key on and engine running and battery voltage > 10
volts.
Set Condition: The EGR solenoid control circuit is not in the expected state when
requested to operate by the PCM.
POSSIBLE CAUSES
EGR SOLENOID DEFECTIVE
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EGR SOLENOID CIRCUIT WIRING HARNESS INTER DEFECT
EGR SOLENOID CIRCUIT WIRING HARNESS OBSERVABLE DEF
EGR SOLENOID CONTROL CIRCUIT OPEN
EGR SOLENOID CONTROL CIRCUIT SHORT TO GROUND
PCM DEFECTIVE (EGR SOL CKT)
TEST ACTION APPLICABILITY
1 Ignition On, Engine Not Running
With the DRB, read the codes.
Is the Global Good Trip displayed and equal to 0?All
Ye s®Go To 2
No®Go To 7
2 Ignition Off
Disconnect the EGR Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Turn ignition on with engine not running.
Using the DRB, actuate the EGR Solenoid.
Using a Voltmeter, probe the Fused Ignition Switch Output Circuit at the EGR
Solenoid Connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 3
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-2A.
133
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TEST ACTION APPLICABILITY
3Note: Leaving the Gas Cap loose could cause this trouble code to set.
To continue testing you will need Miller Tool Kit #6872A and #8382.
NOTE: The Fuel Tank must have 1/2 tank of fuel to perform this test.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Warning: Verify the vehicle fuel tank contains at least 3 gallons of fuel.
Attach the DRB III to the vehicle.
Turn the Key On.
At: ENGINE SYSTEM TESTS select: LEAK DETECTION PUMP TEST.
Read instructions and then press ENTER.
At: LEAK DETECTION PUMP TEST select #3 HOLD PSI.
At the vacuum hose going to the LDP, attach and apply a continuous vacuum (i.e. 209
Hg).
Remove Gas Cap.
Install 8382 on the Gas Cap and on the vehicle.
Attach the supply hose from 6872A to 8382.
Attach the power source from the 6872A, clip to Battery(+) and ground clip to
Battery(-).
On the 6872A set the Pressure/Hold Valve to Open and set the Vent Valve to Closed.
Turn the timer on and watch the gauge.
When the gauge pressure reaches 14 in. H2O, turn the Pressure/Hold Valve to
Closed.
Turn the timer off. Note the time and pressure.
Did pressure drop more than 6 in. H2O (to 8 inches H2O on the gauge) in two
minutes?All
Ye s®Go To 4
No®Go To 5
141
DRIVEABILITY
P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED ÐContinued
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TEST ACTION APPLICABILITY
4 To continue testing you will need Miller Tool Kit #6872A, #8382 and #6904 Ultrasonic
Leak Detector.
NOTE: The Fuel Tank must have 1/2 tank of fuel to perform this test.
Perform Evaporative System Pressure Pump Self Test that is specified on the tester
cover.
Warning: Verify the vehicle fuel tank contains at least 3 gallons of fuel.
Attach the DRB III to the vehicle.
Turn the Key On.
At: ENGINE SYSTEM TESTS select: LEAK DETECTION PUMP TEST.
Read instructions and then press ENTER.
At: LEAK DETECTION PUMP TEST select #3 HOLD PSI.
At the vacuum hose going to the LDP, attach and apply a continuous vacuum (i.e. 209
Hg).
Remove Gas Cap.
Install 8382 on the Gas Cap and on the vehicle.
Attach the supply hose from 6872A to 8382.
Attach the power source from the 6872A, clip to Battery(+) and ground clip to
Battery(-).
Set Pressure Hold to Open and set Vent to Open.
Turn Pump Timer On.
To prevent noise from interfering with test, move tool #6872 away from vehicle.
Using the Ultrasonic Leak Detector, start listening for leaks at Gas Cap then proceed
to Rollover Valve, Canister, Leak Detection Pump, and Evap Purge Solenoid.
Were any leaks heard with the Ultrasonic Leak Detector?All
Ye s®Repair or replace leaking component.
Perform VERIFICATION TEST VER-6A.
No®Replace Leak Detection Pump.
Perform VERIFICATION TEST VER-6A.
5 At this time, the condition required to set the code is not present.
Using the schematic as a guide, inspect the wiring, connectors and hoses.
Were any problems found?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-6A.
No®Test Complete.
142
DRIVEABILITY
P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED ÐContinued
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Symptom:
P-0443 EVAP PURGE SOLENOID CIRCUIT
When Monitored and Set Condition:
P-0443 EVAP PURGE SOLENOID CIRCUIT
When Monitored: With the ignition key on and the engine running.
Set Condition: After arming conditions are satisfied: not powering down, not already in
limp-in, time since last solenoid activation > 72 micro seconds. The PCM will set a trouble
code if the actual sate of the solenoid does not match the intended state.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
PROPORTIONAL EVAP PURGE SOLENOID DEFECTIVE
EVAP PURGE SOL CKT WIRING HARNESS INTERMITTENT DEF
EVAP PURGE SOLENOID CKT WIRING HARNESS OBS DEFECT
EVAP PURGE SOLENOID CONTROL CIRCUIT OPEN
EVAP PURGE SOLENOID CONTROL CIRCUIT SHORT TO GND
PROPORTIONAL PURGE SOL CONTROL CKT SHORT TO GROUND
PROPORTIONAL PURGE SOLENOID CONTROL CIRCUIT OPEN
PWM PURGE SENSE CIRCUIT OPEN
PWM PURGE SENSE CIRCUIT SHORT TO GROUND
POWERTRAIN CONTROL MODULE DEFECTIVE
TEST ACTION APPLICABILITY
1 Is the vehicle equipped with a Proportional Purge solenoid? ALL
Ye s®Go To 10
No®Go To 2
2 Ignition On, Engine Not Running.
With the DRB, actuate the Evap Purge Solenoid.
With the DRB, read codes.
Is the Global Good Trip displayed and equal to 0?ALL
Ye s®Go To 3
No®Go To 8
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TEST ACTION APPLICABILITY
3 Ignition Off.
Disconnect the Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Key On.
Using a Voltmeter, measure the voltage of the Ignition Switch Output Circuit at
Solenoid Connector.
Is the voltage above 10.0 volts?ALL
Ye s®Go To 4
No®Repair the open Fused Ignition Switch Output Circuit.
Perform Powertrain Verification Test VER-5A.
4 Ignition Off.
Disconnect the Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Key On.
Connect a test light from the Evap Purge Solenoid Control EKT to the Ignition
Switch out CKT.
Using a DRB, actuate the Evap Purge Solenoid.
Does the test light flash on and off?ALL
Ye s®Replace the Evap Purge Solenoid.
Perform Powertrain Verification Test VER-5A.
No®Go To 5
5 Ignition Off.
Disconnect Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Evap Purge Solenoid Control Circuit.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 6
No®Repair the open Evap Purge Solenoid Control Circuit.
Perform Powertrain Verification Test VER-5A.
6 Ignition Off.
Disconnect Evap Purge Solenoid Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Evap Purge Solenoid Control Circuit at Connector
to Ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the Evap Purge Solenoid Control Circuit short to Ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 7
7 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ALL
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
144
DRIVEABILITY
P-0443 EVAP PURGE SOLENOID CIRCUIT ÐContinued
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