2000 CHRYSLER VOYAGER fuel pressure

Symptom:
* CHECKING THE FUEL SYSTEM
POSSIBLE CAUSES
FUEL PUMP GROUND CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN
FUEL PUMP RELAY FUSED B(+) CIRCUIT OPEN
FUEL PUMP RELAY FUSED B(+) CIRCUIT OPEN
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL FILTER DEFECTIVE
FUEL FILTER DEFECTIVE
FUEL PUMP DEFECTIVE
FUEL PUMP DEFECTIVE
FUEL PUMP RELAY
FUEL PUMP RELAY
IN-TANK FUEL PRESSURE REGULATOR DEFECTIVE
IN-TANK FUEL PRESSURE REGULATOR DEFECTIVE
THROTTLE POSITION SENSOR DEFECTIVE
FUEL FILTER DEFECTIVE
FUEL FILTER DEFECTIVE
FUEL INLET STRAINER DEFECTIVE
FUEL INLET STRAINER DEFECTIVE
FUEL PUMP MODULE DEFECTIVE
FUEL PUMP MODULE DEFECTIVE
FUEL SUPPLY LINE DEFECTIVE
FUEL SUPPLY LINE DEFECTIVE
FUEL TUBE RESTRICTED
FUEL TUBE RESTRICTED
POWERTRAIN CONTROL MODULE DEFECTIVE
POWERTRAIN CONTROL MODULE DEFECTIVE
THROTTLE CABLES DEFECTIVE
THROTTLE CABLES DEFECTIVE
THROTTLE POSITION SENSOR DEFECTIVE
278
STARTING
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TEST ACTION APPLICABILITY
1Note: Ensure the SKIM has proper communication and that there are no
SKIM DTC's present before continuing.
Ignition Off.
Ensure the Throttle Cables are not holding the Throttle open.
Is the Throttle held open?ENGINE - 3.0L V6
Ye s®Repair condition that holds the Throttle Body open.
Perform Powertrain Verification Test VER-1A.
No®Go To 2
2 Ignition On, Engine Not Running
With the DRB, actuate the Fuel System and check for Fuel Pump operation at the
Fuel Tank.
Is the Fuel Pump operating?ENGINE - 3.0L V6
Ye s®Go To 3
No®Go To 13
3 Ignition On, Engine Not Running
With DRB, read Throttle Position Sensor voltage.
Is the voltage above 1.5 volts?ENGINE - 3.0L V6
Ye s®Disconnect the TP Sensor Conn. Replace Throttle Position Sensor.
Perform Powertrain Verification Test VER-1A.
No®Go To 4
4 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Install a Fuel Pressure Gauge to the Fuel Rail.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 psi for Gasoline.
Is the Fuel pressure above the specification ?ENGINE - 3.0L V6
Ye s®Go To 5
No®Go To 8
5 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 6
279
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
6 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Go To 7
No®Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-1A.
7 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Return Tube for restriction between fuel Filter and Fuel Pump Module.
Is there a restriction?ENGINE - 3.0L V6
Ye s®Replace restricted Fuel Tube.
Perform Powertrain Verification Test VER-1A.
No®Test Complete.
8 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Tee-In a Fuel Pressure Gauge into the Fuel Hose using tool #6433.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 psi for Gasoline.
Is the Fuel pressure below the specification ?ENGINE - 3.0L V6
Ye s®Go To 9
No®Test Complete.
9 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove adapter 6631 and reinstall Fuel Line.
Install adapter 6631 between Fuel Pump and Fuel Filter.
Connect Fuel Pressure Gauge to adapter 6631.
Key on.
With the DRB, actuate Fuel System.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 3.0L V6
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 10
280
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
10 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pump Module.
Inspect the Fuel Pump Inlet Strainer.
Is the Inlet Strainer plugged?ENGINE - 3.0L V6
Ye s®Replace the Fuel Inlet Strainer.
Perform Powertrain Verification Test VER-1A.
No®Go To 11
11 Record the Fuel Pressure Gauge reading.
Ignition key off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pressure Gauge.
Remove Fuel Pressure Gauge Adapter 6433 and reconnect Fuel Line to Fuel Rail.
Install adapter 6631 between Fuel Filter Outlet and Chassis Fuel Supply Tube.
Connect Fuel Pressure Gauge to adapter 6631.
Ignition On, Engine Not Running.
With DRB, actuate the ASD Fuel System.
Record the Fuel Pressure Gauge reading.
Compare this reading with the previous reading.
Is the fuel pressure at least 2 psi higher than the previous reading?ENGINE - 3.0L V6
Ye s®Repair restriction in Chassis Fuel Supply Line between Fuel
Filter and Fuel Rail.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
12 If there are no potential causes remaining, the Fuel Pump Module is assumed to be
defective.
View repair options.ENGINE - 3.0L V6
Repair
Replace Fuel Pump Module.
Perform Powertrain Verification Test VER-1A.
13 Ignition On, Engine Not Running
With DRB, read Throttle Position Sensor voltage.
Is the voltage above 1.5 volts?ENGINE - 3.0L V6
Ye s®Disconnect the TP Sensor Conn. Replace Throttle Position Sensor.
Perform Powertrain Verification Test VER-1A.
No®Go To 14
14 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.
With an Ohmmeter, measure the Fuel Pump Ground Circuit.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 15
No®Repair the open Fuel Pump Ground Circuit.
Perform Powertrain Verification Test VER-1A.
281
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
20 Ignition On, Engine Not Running
With the DRB, actuate the Fuel System and check for Fuel Pump operation at the
Fuel Tank.
Is the Fuel Pump operating?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 21
No®Go To 30
21 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Install a Fuel Pressure Gauge to the Fuel Rail.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
For 3.3 liter engines fuel pressure should be 50 to 60 psi, and for all other engines fuel
pressure should be 43 to 53 psi.
Is the Fuel pressure above the specification ?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 22
No®Go To 25
22 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction?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 Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 23
23 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Filter for a restriction.
Is there a restriction ?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 24
No®Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-1A.
283
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
24 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release the Fuel pressure.
Inspect Fuel Return Tube for restriction between fuel Filter and Fuel Pump Module.
Is there a restriction ?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 restricted Fuel Tube.
Perform Powertrain Verification Test VER-1A.
No®Test Complete.
25 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve Fuel pressure.
Tee-In a Fuel Pressure Gauge into the Fuel Hose using tool #6433.
Note: The Fuel Tank must be at least 1/4 full for the following tests.
Ignition On, Engine Not Running.
With the DRB, actuate the Fuel System.
Read the Fuel Pressure Gauge.
Fuel pressure should be 43 to 53 PSI for Gasoline, 50 to 60 PSI for (E85) Ethanol.
Is the Fuel pressure below the specification ?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 26
No®Test Complete.
26 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove adapter 6631 and reinstall Fuel Line.
Install adapter 6631 between Fuel Pump and Fuel Filter.
Connect Fuel Pressure Gauge to adapter 6631.
Key On.
With the DRB, actuate Fuel System.
Is the fuel pressure at least 2 psi higher than the previous reading?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 Filter.
Perform Powertrain Verification Test VER-1A.
No®Go To 27
27 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pump Module.
Inspect the Fuel Pump Inlet Strainer.
Is the Inlet Strainer plugged?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 Inlet Strainer.
Perform Powertrain Verification Test VER-1A.
No®Go To 28
284
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
28 Record the Fuel Pressure Gauge reading.
Ignition Key Off.
Warning: The Fuel System must be opened and may be under high pressure.
Release Fuel pressure.
Remove the Fuel Pressure Gauge.
Install adapter 6631 between Fuel Filter Outlet and Chassis Fuel Supply Tube.
Connect Fuel Pressure Gauge to adapter 6631.
Ignition On, Engine Not Running.
With DRB, actuate the ASD Fuel System.
Record the Fuel Pressure Gauge reading.
Compare this reading with the previous reading.
Is the fuel pressure at least 2 psi higher than the previous reading?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®Repair restriction in Chassis Fuel Supply Line between Fuel
Filter and Fuel Rail.
Perform Powertrain Verification Test VER-1A.
No®Go To 29
29 If there are no potential causes remaining, the Fuel Pump Module 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 Fuel Pump Module.
Perform Powertrain Verification Test VER-1A.
30 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.
With an Ohmmeter, measure the Fuel Pump Ground Circuit.
Is the resistance below 5.0 ohms?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 31
No®Repair the open Fuel Pump Ground Circuit.
Perform Powertrain Verification Test VER-1A.
31 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Ignition On , Engine Not Running.
With a Voltmeter, measure the Fuel Pump Relay Fused B(+) 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 32
No®Repair the open Fuel Pump Relay Fused B(+) Circuit.
Perform Powertrain Verification Test VER-1A.
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STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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POWERTRAIN CONTROL MODULE C1 - BLACK 40 WAYCAV CIRCUIT FUNCTION
1- -
2 K18 18RD/YL IGNITION COIL NO. 3 DRIVER
3 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
4- -
5 V32 18YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
6 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
7 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
8 K20 18DG GENERATOR FIELD DRIVER (+)
9- -
10 Z12 18BK/TN GROUND
11 K19 18GY/RD IGNITION COIL NO. 1 DRIVER
12 - -
13 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
14 K58 18BR/DB FUEL INJECTOR NO. 6 DRIVER
15 K38 18GY FUEL INJECTOR NO. 5 DRIVER
16 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
17 K12 18TN/WT FUEL INJECTOR NO. 2 DRIVER
18 - -
19 - -
20 F87 18WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
21 - -
22 G3 18BK/PK SERVICE ENGINE SOON INDICATOR DRIVER
23 - -
24 - -
25 K42 18DB/LG KNOCK SENSOR SIGNAL
26 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
27 K127 18BK/OR OXYGEN SENSOR GROUND
28 - -
29 - -
30 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
31 K90 18TN (EXCEPT 3.0L) SMART START RELAY CONTROL
32 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
34 - -
35 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
36 K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
37 K21 18BK/RD (2.4L) INTAKE AIR TEMPERATURE SIGNAL
38 C103 18DG/LB (EXCEPT
3.0L)A/C SWITCH SIGNAL
39 - -
40 K35 18GY/YL EGR SOLENOID CONTROL
C
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N
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C
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O
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P
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349
CONNECTOR PINOUTS
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