2000 CHRYSLER VOYAGER fuel

TEST ACTION APPLICABILITY
8 Ignition Off
Inspect the Chassis Fuel Supply Line to engine for a kink or restriction.
Is the Line kinked or restricted?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 9
9 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is the Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Release the Fuel Pressure. Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Go To 10
10 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Connect a Fuel Pressure Adapter and Gauge to Supply Line between Tank/Filter.
Turn ignition on.
With the DRB, actuate the Fuel System test.
Is Fuel Pressure at least 5 psi higher than previously recorded pressure?ENGINE - 2.4L I-4
DOHC and/or EN-
GINE - 3.3L V6
and/or ENGINE -
3.3L V6 FFV and/or
ENGINE - 3.8L V6
Ye s®Test Complete.
No®Release the Fuel Pressure. Replace the Fuel Pump and Regulator
Assembly.
Perform Powertrain Verification Test VER-2A.
11 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Relieve the Fuel Pressure.
Tee-in Fuel Pressure Gauge into the Fuel Supply Hose using Tool #6433.
Turn ignition on.
With the DRB, actuate the ASD Fuel System test.
Is the Fuel Pressure between 43 and 53 psi?ENGINE - 3.0L V6
Ye s®Go To 12
No®Go To 15
12 Ignition Off
Note: Make sure the Gear Lever is in neutral, and the Park Brakes engaged.
Start the engine.
Monitor the Fuel Pressure Gauge in the next step.
While monitoring the pressure, momentarily snap Throttle wide open raising RPM to
above 3000.
Did the fuel pressure drop below 35 psi at all?All
Ye s®Go To 13
No®Test Complete.
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* CHECKING FUEL DELIVERY ÐContinued
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TEST ACTION APPLICABILITY
13 Ignition Off
Inspect the Chassis Fuel Supply Line to the engine for a kink or restriction.
Is the line kinked or restricted?All
Ye s®Release the fuel pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 14
14 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Adjust a shop air hose to 40 psi.
Remove the Fuel Filter.
Using shop air, inspect the Fuel Filter passage by attempting to blow air through
inlet.
Is the Fuel Filter restricted?All
Ye s®Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Replace the Fuel Pump and Regulator Assembly.
Perform Powertrain Verification Test VER-2A.
15 Ignition Off.
Warning: The Fuel System must be opened and may be under high pressure.
Relieve the Fuel Pressure.
Tee-in Fuel Pressure Gauge into the Fuel Supply Hose using Tool #6433.
Turn Ignition On.
With the DRB, actuate the ASD Fuel System test.
Record the Fuel Pressure reading.
Is the Fuel Pressure above 53 psi?ENGINE - 3.0L V6
Ye s®Go To 16
No®Go To 18
16 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Remove the Fuel Pressure Gauge from the Fuel Rail.
Remove the Fuel Return Line between the Fuel Tank and Filter.
Adjust a shop air hose to 40 psi.
Using shop air, inspect the Fuel Line by attempting to blow air through it.
Is the Fuel Return Line restricted?All
Ye s®Replace the Fuel Return Line.
Perform Powertrain Verification Test VER-2A.
No®Go To 17
17 If there are no potential causes remaining, the Fuel Pressure Regulator is assumed
to be defective.
View repair options.All
Repair
Replace the Fuel Pressure Regulator.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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TEST ACTION APPLICABILITY
18 Ignition Off
Inspect the Chassis Fuel Supply Line to engine for a kink or restriction.
Is the Fuel Line kinked or restricted?ENGINE - 3.0L V6
Ye s®Release the Fuel Pressure. Repair the Fuel Line as necessary.
Perform Powertrain Verification Test VER-2A.
No®Go To 19
19 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Install Fuel Pressure Gauge between Fuel Tank and Fuel Filter.
Key on.
With the DRB, actuate the ASD Fuel System test.
Is fuel pressure at least 5 psi higher than the previously recorded pressure?ENGINE - 3.0L V6
Ye s®Release the Fuel Pressure. Replace the Fuel Filter.
Perform Powertrain Verification Test VER-2A.
No®Go To 20
20 Ignition Off
Warning: The Fuel System must be opened and may be under high pressure.
Release the fuel pressure.
Install Fuel Pressure Gauge between Fuel Tank and Fuel Filter.
Key on.
With the DRB, actuate the ASD Fuel System test.
Is fuel pressure at least 5 psi higher than the previously recorded pressure?ENGINE - 3.0L V6
Ye s®Test Complete.
No®Release the Fuel Pressure. Replace the Fuel Pump and Regulator
Assembly.
Perform Powertrain Verification Test VER-2A.
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DRIVEABILITY
* CHECKING FUEL DELIVERY ÐContinued
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Symptom:
* CHECKING THE ENGINE MECHANICAL SYSTEMS
POSSIBLE CAUSES
CHECKING ENGINE MECHANICAL SYSTEMS
TEST ACTION APPLICABILITY
1 At this point in the diagnostic test procedure, you have determined that all of the
engine electrical systems are operating as designed; therefore, they are not the cause
of the driveability problem.
The following additional items should be checked as possible mechanical causes of
the problem:
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
CAMSHAFT LOBES - check for abnormal wear
CRANK SENSOR PICK-UP - check crankshaft slots for debris/deterioration
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
Note: If you came to this test from the oxygen sensor, and the rich or lean
condition is not caused by one of the first items above, replace the power-
train control module and perform TEST VER-2A (Road Test Verification).
Always look for any Technical Service Bulletins that may relate to the problem.
Did you come from an Oxygen Sensor rich or lean condition test?All
Ye s®Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-2A.
No®Test Complete.
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Symptom:
*(NO RESPONSE(CONDITION
POSSIBLE CAUSES
IGNITION NOT ON
DIAGNOSTIC READ-OUT BOX ADAPTER CABLE DEFECTIVE
FUEL PUMP DEFECTIVE
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
PCM GROUNDS OPEN
FUEL PUMP RELAY OUT CKT INTERMITTENT SHORT TO GRND
FUEL PUMP RELAY OUTPUT CIRCUIT SHORT TO GROUND
SCI RECEIVE CIRCUIT OPEN
SCI RECEIVE CIRCUIT SHORT TO GROUND
SCI TRANSMIT CIRCUIT OPEN
SCI TRANSMIT CIRCUIT SHORTED TO GROUND
FUSED B(+) CIRCUIT OPEN BETWEEN FUSE AND BATTERY
DIAGNOSTIC READ-OUT BOX DEFECTIVE
PCM DEFECTIVE (NO RESPONSE)
FUSED B(+) CIRCUIT OPEN BETWEEN FUSE AND PCM
FUSED B(+) CIRCUIT SHORT TO GROUND
TEST ACTION APPLICABILITY
1 Attempt to start vehicle.
Does the vehicle start?All
Ye s®Go To 2
No®Go To 12
2 Was the Ignition on when the ªNo Responseº message was displayed? All
Ye s®Go To 3
No®Turn the ignition on to get a response.
3 Ignition off.
Using an Ohmmeter, measure the DLC ground circuit (terminals 4 and 5) to ground.
Is the resistance below 5.0 ohms for each measurement?All
Ye s®Go To 4
No®Repair the open ground circuit(s).
Perform Powertrain Verification Test VER-1A.
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TEST ACTION APPLICABILITY
14 Ignition Off.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Turn the ignition on.
With a voltmeter, mesure the Fused B(+) Curcuit.
Is the voltage above 10.0 volts?All
Ye s®Go To 15
No®Go To 16
15 If there are no potential causes remaining, replace the Powertrain Control Module.
View repair options.All
Replace the Powertrain Control Module.
Perform the Powertrain Verification Test VER-1A.
16 Remove Fuel Pump Fuse from the Power Distribution Center.
Inspect the Fuse.
Is the fuse OK?All
Ye s®Go To 17
No®Go To 18
17 Ignition On.
Remove the Fuel Pump Fuse from the PCM.
With a voltmeter, measure the B(+) side of the Fuse Socket.
Is the voltage above 10.0 volts?All
Ye s®Repair the opem B(+) circuit between the Fuse and the PCM.
Perform Powertrain Verification Test VER-1A.
No®Repair the opem B(+) circuit between the Fuse and the battery.
Perform Powertrain Verification Test VER-1A.
18 Ignition Off
Disconnect the Fuel Pump Relay.
Disconnect the Fuel Pump Electrical Connector.
Note: Check connectors - Clean/repair as necessary.
With an Ohmmeter, measure the Fuel Pump Relay Output Circuit to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Fuel Pump Relay Output Circuit for a short to ground.
Perform Powertrain Verification Test VER-1A.
No®Go To 19
19 If there are no potential causes remaining, the Fuel Pump is assumed to be defective.
View repair options.All
Repair
Replace the Fuel Pump. Replace Fuel Pump Fuse.
Perform Powertrain Verification Test VER-1A.
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*(NO RESPONSE(CONDITION ÐContinued
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Symptom:
* CHECKING THE ENGINE MECHANICAL SYSTEMS
POSSIBLE CAUSES
ENGINE COMPRESSION OUT OF SPECIFICATION
VALVE TIMING OUT OF SPECIFICATION
POWERTRAIN CONTROL MODULE DEFECTIVE
CLEAN SPARK PLUGS
SPARK PLUG CABLES POSITIONED INCORRECTLY
TEST ACTION APPLICABILITY
1 Turn Ignition off.
Inspect Spark Plug Cables for correct placement.
Are all Spark Plug Cables positioned correctly?All
Ye s®Go To 2
No®Reinstall Spark Plug Cables as necessary.
2 Turn Ignition off.
Remove all Spark Plugs and inspect the tips for wet fuel.
Are the Spark Plug tips wet?All
Ye s®Clean the spark plugs.
No®Go To 3
3 Turn Ignition off.
Using service information procedures, check Engine compression.
Is Engine compression within specifications?All
Ye s®Go To 4
No®Repair the Engine as necessary.
Perform Verification Test VER-1A.
4 Turn Ignition off.
Using service information procedures, check Engine Valve timing.
Is Valve timing within specifications?All
Ye s®Go To 5
No®Repair Valve timing as necessary.
Perform Verification Test VER-1A.
5 If there are no potential causes or DTCs 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-1A.
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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
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