2000 CHRYSLER VOYAGER check engine

Symptom:
P-0204 INJECTOR #4 CONTROL CIRCUIT
When Monitored and Set Condition:
P-0204 INJECTOR #4 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 #4 DEFECTIVE
INJECTOR #4 DRIVER CIRCUIT OPEN
INJECTOR #4 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?ALL
Ye s®Go To 2
No®Go To 7
2Note: It may be necessary to remove the Intake Plenum in the following
steps.
Key off.
Disconnect the #4 Injector Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure resistance of Injector #4.
Is the resistance between 10.0 and 16.0 ohms?ALL
Ye s®Go To 3
No®Replace the Fuel Injector.
Perform Powertrain Verification Test VER-5A.
92
DRIVEABILITY
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TEST ACTION APPLICABILITY
3Note: It may be necessary to remove the Intake Plenum in the following
steps.
Disconnect the #4 Injector Connector.
Note: Check connectors - Clean/repair as necessary.
Turn 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?ALL
Ye s®Go To 4
No®Repair the open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-5A.
4Note: It may be necessary to remove the Intake Plenum in the following
steps.
Key off.
Disconnect the Injector #4 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure across the Injector #4 Driver Circuit from the PCM to
the Injector.
Is the resistance below 5.0 ohms?ALL
Ye s®Go To 5
No®Repair the open Injector #4 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5Note: It may be necessary to remove the Intake Plenum in the following
steps.
Key off.
Disconnect the #4 Injector Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #4 Driver Circuit to ground.
Is the resistance below 5.0 ohms?ALL
Ye s®Repair the Injector #4 Control Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 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.
7 Engine Running
Wiggle Wiring Harness from the Injector to the PCM.
Does the engine miss or stall?ALL
Ye s®Repair as necessary where wiggling caused the problem to
appear.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
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DRIVEABILITY
P-0204 INJECTOR #4 CONTROL CIRCUIT ÐContinued
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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.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
4 Ignition Off
Disconnect Injector #5 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #5 Driver Circuit from the PCM to the
Injector.
Is the resistance below 5.0 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 5
No®Repair the open Injector #5 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5 Ignition Off
Disconnect Injector #5 Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #5 Driver Circuit to ground.
Is the resistance below 5.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair the Injector #5 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 If there are no potential causes remaining, the PCM is assumed to be defective.
View repair options.ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Repair
Replace the PCM.
Perform Powertrain Verification Test VER-5A.
7 Ignition Off
Using the schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
8 Engine Running
Wiggle Wiring Harness from the Injector to the PCM.
Does the engine miss or stall?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair as necessary where wiggling caused the problem to
appear.
Perform Powertrain Verification Test VER-5A.
No®Test Complete.
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DRIVEABILITY
P-0205 INJECTOR #5 CONTROL CIRCUIT ÐContinued
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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.
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DRIVEABILITY
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TEST ACTION APPLICABILITY
3 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.
Turn ignition on.
With the DRB, actuate the ASD 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 Auto Shutdown Relay Output Circuit.
Perform Powertrain Verification Test VER-5A.
4 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.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #6 Driver Circuit from the PCM to the
Injector.
Is the resistance below 5.0 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 5
No®Repair the open Injector #6 Driver Circuit.
Perform Powertrain Verification Test VER-5A.
5 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.
Disconnect the Powertrain Control Module Connector.
Note: Check connectors - Clean/repair as necessary.
Using an Ohmmeter, measure the Injector #6 Driver Circuit to ground.
Is the resistance below 5.0 ohms?ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Repair the Injector #6 Driver Circuit for a short to ground.
Perform Powertrain Verification Test VER-5A.
No®Go To 6
6 It there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.ENGINE - 3.0L,
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-5A.
98
DRIVEABILITY
P-0206 INJECTOR #6 CONTROL CIRCUIT ÐContinued
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TEST ACTION APPLICABILITY
5 With an appropriate container, obtain a fuel sample from the vehicle.
Is the fuel free from contamination?All
Ye s®Go To 6
No®Replace contaminated fuel and clean system.
Perform VERIFICATION TEST VER-5A2.
6 Perform Fuel Pressure Leak Down Test per service instructions.
Did the Fuel Pressure Leak Down Test pass?All
Ye s®Go To 7
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
7 Perform Fuel Pump Amperage Test per service instructions.
Did the Fuel Pump Amperage Test pass?All
Ye s®Go To 8
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
8 Perform Fuel Pump Capacity Test per service instructions.
Did the Fuel Pump Capacity Test pass?All
Ye s®Go To 9
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
9 Perform Fuel Pump Pressure Test per service instructions.
Did the Fuel Pump Pressure Test pass?All
Ye s®Go To 10
No®Relieve fuel pressure and repair as necessary.
Perform VERIFICATION TEST VER-5A2.
10 With the DRB, read the FREEZE FRAME DATA.
Use the freeze frame data and attempt to determine the cause.
In the FREEZE FRAME, is the LOAD VALUE over 50% and the temp normal
operating temp normal?All
Ye s®Go To 12
No®Go To 11
11 With the DRB, read the FREEZE FRAME window.
Use the freeze frame data and attempt to determine the cause.
In the FREEZE FRAME, is the ENGINE RPM over 3000 and the operating temp
normal?All
Ye s®Lab scope cam and crank sensor, check valve timing, running
vacuum test.
Perform VERIFICATION TEST VER-5A2.
No®Go To 14
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DRIVEABILITY
P-0300 MULTIPLE CYLINDER MIS-FIRE ÐContinued
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TEST ACTION APPLICABILITY
12 Engine Off.
Connect a suitable engine analyzer to the engine.
Allow the Engine to idle.
NOTE: If the Engine will not idle, maintain a constant RPM above idle.
NOTE: Set the scope to read display or parade pattern.
Remove any spark plug wire.
Observe the Secondary KV Line.
Is the open secondary voltage at least 25 KV?All
Ye s®Go To 13
No®Replace the Ignition Coil.
Perform VERIFICATION TEST VER-5A2.
13 Engine Off.
Connect a suitable engine analyzer to the engine.
Allow the Engine to idle.
NOTE: If the Engine will not idle, maintain a constant RPM above idle.
NOTE: Set the scope to read display or parade pattern.
Follow the equipment manufacturer's procedure for pattern analysis.
Is the secondary ignition pattern OK?All
Ye s®Go To 14
No®Repair the indicated component in the Secondary Ignition Sys-
tem.
Perform VERIFICATION TEST VER-5A2.
14 The following are possible causes for mis-fire:
Injector harness connectors, ignition coil circuit, spark plug, mechanical engine
problem, PCM power grounds, irregular cam and crank signal, injectors, restricted
exhaust, intake restriction, PCM, Evap System, EGR System, damaged trigger
wheel, and
accessory drive belts.
Do any of the above causes exist?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A2.
No®Go To 15
15The following additional items should be checked as possible mechanical
problems:
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
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
Are there any engine mechanical problems?All
Ye s®Repair as necessary.
Perform VERIFICATION TEST VER-5A2.
No®Test Complete.
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DRIVEABILITY
P-0300 MULTIPLE CYLINDER MIS-FIRE ÐContinued
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