2000 CHRYSLER VOYAGER fuel

Symptom:
P-0441 EVAP PURGE FLOW MONITOR FAILURE
When Monitored and Set Condition:
P-0441 EVAP PURGE FLOW MONITOR FAILURE
When Monitored: With engine temperature greater than 170ÉF, engine in closed loop,
engine idling for 2 minutes, no low fuel, MAP less than 15.7 inches mercury, and
barometric altitude less than 8,000 feet.
Set Condition: Note: with LDP: must pass stricter evap system test first. No air flow
through the evaporative system is detected by the evap monitor.
POSSIBLE CAUSES
PURGE CANISTER LINE DAMAGED
PURGE SOLENOID AND CANISTER DEFECTIVE
PURGE SOLENOID DEFECTIVE
VACUUM HOSES DAMAGED OR PLUGGED
EVAP PURGE MONITOR FAILURE DOES NOT REOCCUR
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP counter displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the Evap Purge Flow Monitor Failure does not exist or is an intermittent
problem.
With the DRB, read the FREEZE FRAME DATA.
With these screens, attempt to duplicate the condition that has set this fault.
While using FREEZE FRAME pay particular attention to the fault setting condi-
tions, such as speed, temp, load, and map vacuum.
Does the Evap Purge Flow Monitor Failure reoccur?All
Ye s®Go To 3
No®The Evap Purge Flow Monitor failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
3NOTE: Carefully inspect all vacuum hoses for proper routing and for
pinched or plugged hoses from the engine to the solenoid to the gas tank.
Are all vacuum hoses OK?All
Ye s®Go To 4
No®Repair the vacuum hoses as necessary.
Perform VERIFICATION TEST VER-5A3.
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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
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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.
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P-0442 EVAP LEAK MONITOR SMALL LEAK DETECTED ÐContinued
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Symptom:
P-0460 FUEL LEVEL UNIT NO CHANGE OVER MILES
POSSIBLE CAUSES
FUEL LEVEL SENSOR WIRING/HARNESS OBSERVABLE DEFECT
FUEL TANK OBSTRUCTED
TEST COMPLETE
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, read the Fuel Level Sensor voltage and make a note of the voltage.
Add two gallons of fuel to the Fuel Tank.
With the DRB, read the Fuel Level Sensor voltage.
Did the Fuel Level Sensor voltage decrease by at least 0.2 volts?All
Ye s®Go To 2
No®Check for an obstruction in the Fuel Tank. If ok replace Fuel
Level Sensor.
Perform Powertrain Verification Test VER-2A.
2 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-2A.
No®Test Complete
Perform Powertrain Verification Test VER-2A.
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Symptom:
P-0462 FUEL LEVEL SENDING UNIT VOLTS TOO LOW
POSSIBLE CAUSES
FUEL LEVEL SENSOR DEFECTIVE
FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FUEL LEVEL SENSOR WIRING/HARNESS INTERMITENT DEFECT
BODY CONTROL MODULE DEFECTIVE
FUEL LEVEL SENSOR WIRING/HARNESS OBSERVABLE DEFECT
TEST COMPLETE
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, read the DTC's.
is the Global Good Trip counter displayed and equal to zero?All
Ye s®Go To 2
No®Go To 5
2 Ignition Off
Disconnect the Fuel Pump Module Harness Connector.
Note: Check connectors - Clean/repair as necessary.
With the DRB, read the Fuel Level Sensor voltage.
Is the Fuel Level Sensor voltage above 4.5 volts?All
Ye s®Replace the Fuel Level Sensor.
Perform Powertrain Verification Test VER-2A.
No®Go To 3
3 Key Off
Disconnect the Body Control Module9B9(GREY) Connector.
Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Fuel Level Sensor Signal Circuit for resistance to
ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Fuel Level Sensor Signal Circuit shorted to ground.
Perform Powertrain Verification Test VER-2A.
No®Go To 4
4 If there are no potential causes remaining, the BCM is assumed to be defective.
View repair options.All
Repair
Replace the Body Control Module.
Perform Powertrain Verification Test VER-2A.
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TEST ACTION APPLICABILITY
5 Ignition On
Use the schematic as a guide and wiggle the Connector & Harness.
Using the DRB, monitor the Fuel Level Sensor voltage.
Was there any Fuel Level Sensor Voltage change?All
Ye s®Repair the Harness or Connector that caused the voltage change.
Perform Powertrain Verification Test VER-2A.
No®Go To 6
6 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-2A.
No®Test Complete
Perform Powertrain Verification Test VER-2A.
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P-0462 FUEL LEVEL SENDING UNIT VOLTS TOO LOW ÐContinued
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Symptom:
P-0463 FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
POSSIBLE CAUSES
FUEL LEVEL SENSOR DEFECTIVE
FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN
FUEL PUMP MODULE WIRING/HARNESS INTERMITENT DEFECT
BODY CONTROL MODULE DEFECTIVE
FUEL PUMP MODULE OBSERVABLE DEFECT
FUEL PUMP MODULE GROUND CIRCUIT DEFECTIVE
TEST COMPLETE
TEST ACTION APPLICABILITY
1 Ignition On
With the DRB, read the DTC's.
Is the Global Good Trip counter dispalyed and equal to zero?All
Ye s®Go To 2
No®Go To 6
2 Key Off
Disconnect the Fuel Pump Module Connector.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper between the Fuel Level Sensor Signal Circuit and the Ground
Circuit at the Fuel Pump Module Connector.
With the DRB, read the Fuel Level Sensor voltage.
Is the voltage below 1.0 volt?All
Ye s®Replace the Fuel Level Sensor.
Perform Powertrain Verification Test VER-2A.
No®Go To 3
3 Key Off
Disconnect the Fuel Pump Module Connector.
Note: Check connectors - Clean/repair as necessary.
Measure resistance of the Ground Circuit at the Fuel Pump Module Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the Ground Circuit as necessary.
Perform Powertrain Verification Test VER-2A.
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TEST ACTION APPLICABILITY
4 Key Off
Disconnect the Fuel Pump Module Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Body Control Module9B9(GREY) Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Fuel Level Sensor Signal Circuit from the BCM to
the Fuel Pump Module Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the open Fuel Level Sensor Signal Circuit.
Perform Powertrain Verification Test VER-2A.
5 If there are no potential causes remaining, the BCM is assumed to be defective.
View repair options.All
Repair
Replace the Body Control Module.
Perform Powertrain Verification Test VER-2A.
6 Ignition On
Using the schematic as a guide, wiggle the Fuel Pump Module Connector and
Harness.
Using the DRB, monitor the Fuel Level Sensor voltage.
Was there any Fuel Level Sensor voltage change?All
Ye s®Repair the Harness or Connector that caused the voltage change.
Perform Powertrain Verification Test VER-2A.
No®Go To 7
7 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-2A.
No®Test Complete.
Perform Powertrain Verification Test VER-2A.
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P-0463 FUEL LEVEL SENDING UNIT VOLTS TOO HIGH ÐContinued
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