2000 CHRYSLER VOYAGER fuel pump

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.
285
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
32 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.
Ignition On, Engine Not Running.
Actuate the ASD Fuel System test.
With a Voltmeter, measure the Fuel Pump Relay Output 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 33
No®Repair the open Fuel Pump Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
33 Ignition Off.
Disconnect the Fuel Pump Relay.
Check connectors - Clean/repair as necessary.
Install a substitute Relay of the same part number for the Fuel Pump Relay.
Attempt to start the Engine.
Does the Engine start?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 Pump Relay.
Perform Powertrain Verification Test VER-1A.
No®Go To 34
34 Ignition Off.
If there are no potential causes remaining, the Fuel Pump 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 the Fuel Pump.
Perform Powertrain Verification Test VER-1A.
286
STARTING
* CHECKING THE FUEL SYSTEM ÐContinued
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GENERATOR (GENERATOR SIDE)CAV CIRCUIT FUNCTION
1 - ASD RELAY OUTPUT
2 - GENERATOR FIELD DRIVER
3- -
4 - B(+)
5 - CASE GROUND
FUEL INJECTOR NO. 6 (3.3L/3.8L) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K58 18BR/DB FUEL INJECTOR NO. 6 DRIVER
FUEL TANK MODULE - LIGHT GRAY 4 WAYCAV CIRCUIT FUNCTION
1 Z1 14BK GROUND
2- -
3 G4 18DB FUEL LEVEL SENSOR SIGNAL
4 A141 16DG/WT FUEL PUMP RELAY OUTPUT
GENERATOR - BLACK 3 WAYCAV CIRCUIT FUNCTION
1 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K20 18DG GENERATOR FIELD DRIVER (+)
3- -
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CONNECTOR PINOUTS
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DIESEL POWER RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K51 20DB/YL DIESEL POWER RELAY CONTROL
86 A0 6RD FUSED B(+)
87 A142 18DG/OR DIESEL POWER RELAY OUTPUT
87A --
ENGINE STARTER MOTOR RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K90 18TN SMART START RELAY CONTROL
86 F45 20YL/RD (EATX) FUSED IGNITION SWITCH OUTPUT (START)
86 T141 20YL/RD (MTX) FUSED IGNITION SWITCH OUTPUT (START)
87 T40 12BR STARTER RELAY OUTPUT
87A --
FRONT BLOWER MOTOR RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 Z1 18BK GROUND
86 F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN)
87 C71 12DB BLOWER MOTOR DRIVER
87A --
FUEL HEATER RELAY (DIESEL)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 Z1 20BK GROUND
86 INTERNAL FUSED IGNITION SWITCH OUTPUT (ST-RUN)
87 A141 16DG/WT FUEL HEATER RELAY OUTPUT
87A --
FUEL PUMP RELAY (GAS)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K31 18BR FUEL PUMP RELAY CONTROL
86 F87 18WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
87 A141 16DG/WT FUEL PUMP RELAY OUTPUT
87A --
HIGH BEAM RELAYCAV CIRCUIT FUNCTION
30 A0 6RD B(+)
85 L324 20WT/LG HIGH BEAM RELAY CONTROL
86 A0 6RD B(+)
87 INTERNAL HIGH BEAM RELAY OUTPUT
87A --
HORN RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 X4 18GY/OR (RHD DIE-
SEL)HORN RELAY CONTROL
85 X4 20GY/OR (EXCEPT RHD
DIESEL)HORN RELAY CONTROL
86 A0 6RD B(+)
87 X2 18DG/RD HORN RELAY OUTPUT
87A --
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CONNECTOR PINOUTS
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POWERTRAIN CONTROL MODULE C2 - GRAY 40 WAYCAV CIRCUIT FUNCTION
41 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
42 C18 18DB A/C PRESSURE SIGNAL
43 K4 18BK/LB SENSOR GROUND
44 K7 18OR 8V SUPPLY
45 - -
46 A14 18RD/WT FUSED B(+)
47 - -
48 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
49 K60 18L/BK IDLE AIR CONTROL NO. 2 DRIVER
50 Z12 18BK/TN GROUND
51 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
52 - -
53 - -
54 - -
55 - -
56 V36 18TN.RD (EXCEPT
3.0L)SPEED CONTROL VACUUM SOLENOID CONTROL
57 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
58 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
59 D1 18VT/BR CCD BUS (+)
60 D2 18WT/BK CCD BUS (-)
61 K6 18VT/WT 5V SUPPLY
62 K29 18WT/PK BRAKE SWITCH SENSE
63 T10 18YL/DG (EATX) TORQUE MANAGEMENT REQUEST SENSE
64 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
65 D21 18PK SCI TRANSMIT
66 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
67 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
68 K52 18PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
69 - -
70 K70 18VT/RD (EXCEPT
3.0L)PULSE WIDTH MODULATED PURGE SENSE
71 - -
72 K107 18DB/WT (3.3L/3.8L) LEAK DETECTION PUMP SWITCH SENSE
72 K107 18YL/BK (2.4L ATX) LEAK DETECTION PUMP SWITCH SENSE
73 K173 14LG/DB RADIATOR FAN RELAY CONTROL
74 K31 18BR FUEL PUMP RELAY CONTROL
75 D20 18LG SCI RECEIVE
76 T41 18BK/WT (2.4L ATX) TRS T41 SENSE
76 T41 18BR/YL (EATX) TRS T41 SENSE
77 K106 18WT/DG (EXCEPT
3.0L)LEAK DETECTION PUMP SOLENOID CONTROL
78 K54 18OR/BK (2.4L ATX) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
78 V36 18TN/RD (3.0L) SPEED CONTROL VACUUM SOLENOID CONTROL
79 - -
80 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
RADIATOR FAN NO. 1 - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 C23 12DG LOW SPEED RADIATOR FAN RELAY OUTPUT
2 Z1 12BK GROUND
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CONNECTOR PINOUTS
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