2000 CHRYSLER VOYAGER change time

1.0 INTRODUCTION
The procedures contained in this manual include
specifications, instructions, and graphics needed to
diagnose the PCM Powertrain System. The diag-
nostics in this manual are based on the failure
condition or symptom being present at time of
diagnosis.
Please follow the recommendations below when
choosing your diagnostic path.
1. First make sure the DRBIIItis communicating
with the appropriate modules; ie., if the DRBIIIt
displays a ``No Response'' condition, you must
diagnose this first before proceeding.
2. Read DTC's (diagnostic trouble codes) with the
DRBIIIt.
3. If no DTC's are present, identify the customer
complaint.
4. Once the DTC or customer complaint is identi-
fied, locate the matching test in the Table of
Contents and begin to diagnose the symptom.
All component location views are in Section 8.0.
All connector pinouts are in Section 9.0. All system
schematics are in Section 10.0.
An * placed before the symptom description indi-
cates a customer complaint.
When repairs are required, refer to the appropri-
ate service manual for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added; carryover sys-
tems may be enhanced. READ THIS MANUAL
BEFORE TRYING TO DIAGNOSE A VEHICLE
CODE. It is recommended that you review the
entire manual to become familiar with all new and
changed diagnostic procedures.
After using this book, if you have any comments
or recommendations, please fill out the form at the
back of the book and mail it back to us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers the
following 2000 Chrysler Caravan Voyager vehicles
equipped with the 2.0L, 2.4L DOHC, 3.0L MPI,
3.3L/3.8L MPI, or 3.3L E85 compatible Engine.
1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the powertrain control module
(PCM) is done in six basic steps:
²verification of complaint
²verification of any related symptoms
²symptom analysis
²problem isolation
²repair of isolated problem
²verification of proper operation
2.0 IDENTIFICATION OF
SYSTEM
The Powertrain Control Module (PCM) monitors
and controls:
²Fuel system
²Ignition system
²charging system
²speed control system
²cooling system
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
These Sequential Fuel Injection (SFI) engine sys-
tems have the latest in technical advances. The
on-board Euro Stage III On-Board Diagnostic incor-
porated with the powertrain control module (PCM)
are intended to assist the field technician in repair-
ing vehicle problems by the quickest means.
3.2 FUNCTION OPERATION
3.2.1 FUEL CONTROL
The PCM controls the air/fuel ratio of the engine
by varying fuel injector on time. Mass air flow is
calculated using the speed density method using
engine speed, manifold absolute pressure, and air
temperature change.
Different fuel calculation strategies are used de-
pendent on the operational state of the engine.
During crank mode, a prime shot fuel pulse is
delivered followed by fuel pulses determined by a
crank time strategy. Cold engine operation is deter-
mined via an open loop strategy until the O2
sensors have reached operating temperature. At
this point, the strategy enters a closed loop mode
where fuel requirements are based upon the state of
the O2 sensors, engine speed, MAP, throttle posi-
tion, air temperature, battery voltage, and coolant
temperature.
1
GENERAL INFORMATION
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CHECKING FOR OXYGEN
SENSOR SWITCHING
CHECKING O2S HEATER
CHECKING IDLE AIR CON-
TROL MOTOR OPERATION
CHECKING ENGINE ME-
CHANICAL SYSTEMS
CHECKING EVAP EMISSION
SYSTEM
CHECKING EGR SYSTEM
CHECKING IAT SENSOR
CHECKING PNP SWITCH
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser 's guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIItfunctions.
3.5 DRB ERROR MESSAGES AND BLANK
SCREEN
Under normal operation, the DRBIIItwill dis-
play one of only two error messages:
± User-Requested WARM Boot or User-
Requested COLD Boot.
This is a sample of such an error message display:
ver: 2.14
date: 26 Jul93
file: key_itf.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
3.5.1 DRB IIITDOES NOT POWER UP
If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage (data link
connector cavity 16). A minimum of 11 volts is
required to adequately power the DRBIIIt.
If all connections are proper between the
DRBIIItand vehicle or other devices, and the
vehicle battery is fully charged, an inoperative
DRBIIItmay be the result of a faulty cable or
vehicle wiring. For a blank screen, refer to the
appropriate body diagnostics manual.
3.5.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially impor-
tant to block the wheels on front-wheel drive vehicles;
the parking brake does not hold the drive wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing a powertrain system problem,
it is important to follow approved procedures where
11
GENERAL INFORMATION
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TEST ACTION APPLICABILITY
4 Turn the ignition on.
With the DRB, read the FREEZE FRAME DATA.
Using the FREEZE FRAME DATA, attempt to duplicate the condition that has set
this fault.
While using the FREEZE FRAME DATA, pay particular attention to the fault setting
conditions, such as vehicle speed, engine temperature, vehicle load, and MAP
vacuum.
Does P0121 reset?All
Ye s®Go To 6
No®Go To 5
5 Ignition Off
Start engine.
With the DRB, read the MAP Sensor voltage.
Did the MAP Sensor voltage drop from above 3.5 volts to below 2.0 volts?All
Ye s®Go To 6
No®Refer to symptom * CHECKING MAP SENSOR CALIBRATION
in the DRIVEABILITY category.
6 Ignition On, Engine Not Running
Using the schematic as a guide, wiggle the TPS Harness and Connectors to PCM.
While monitoring the DRB, observe for the TPS voltage to change.
Did the TPS voltage change at any time?All
Ye s®Repair the Harness or Connectors as necessary.
Perform Powertrain Verification Test VER-5A.
No®Go To 7
7 Ignition On, Engine Not Running
With the DRB, read the Throttle Position Sensor voltage.
Is the Throttle Position Sensor voltage above 1.0 volt?All
Ye s®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
No®Go To 8
8 Ignition On, Engine Not Running
While monitoring the DRB, open the Throttle Plate to wide open throttle.
Is the Throttle Position Sensor voltage above 3.5 volts?All
Ye s®Go To 9
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
9 Ignition On, Engine Not Running
While monitoring the DRB slowly open and close the Throttle Plate.
Note: You must move linkage very slowly while looking for a jump in
voltage.
Is the voltage change smooth?All
Ye s®Go To 10
No®Replace the Throttle Position Sensor.
Perform Powertrain Verification Test VER-5A.
43
DRIVEABILITY
P-0121 TPS VOLTAGE DOES NOT AGREE WITH MAP ÐContinued
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TEST ACTION APPLICABILITY
8 Ignition Off
Disconnect the Crank Position (CKP) Sensor Connector.
Note: Check connectors - Clean/repair as necessary.
Connect one end of a jumper wire to the Crank Position Signal Circuit.
Turn ignition on.
With the DRB, monitor the current CKP state.
Tap the other end of jumper to Sensor ground several times.
Does the CKP state change to present?All
Ye s®Go To 9
No®Go To 10
9 Ignition Off
Remove the Crankshaft Position (CKP) Sensor.
Inspect the Flywheel for damage. (3.0L, 3.3L and 3.8L)
Inspect the Crankshaft Notches for debris or damage.
Is the Flywheel damaged?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-2A.
No®Replace the Crankshaft Position Sensor.
Perform Powertrain Verification Test VER-2A.
10 Ignition Off
Disconnect the Crank Position (CKP) Sensor 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 resistance of the CKP Signal Circuit to a good ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Crank Position Sensor Signal Circuit for a short to
ground. Note: Check TCM for short.
Perform Powertrain Verification Test VER-2A.
No®Go To 11
11 Ignition Off
Disconnect the Crank Position (CKP) Sensor 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 resistance of the CKP Sensor Signal Circuit from
the CKP Sensor Connector to the PCM Connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 12
No®Repair the open Crank Position Sensor Signal Circuit.
Perform Powertrain Verification Test VER-2A.
11 0
DRIVEABILITY
P-0320 NO CRANK REFERENCE SIGNAL AT PCM ÐContinued
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Symptom:
P-0401 EGR SYSTEM FAILURE
When Monitored and Set Condition:
P-0401 EGR SYSTEM FAILURE
When Monitored: With engine temp > than 82 degrees C (180 degrees F), ambient temp
> 4 degrees C (40 degrees F), engine in closed loop, O2 Sensor operational, engine under a
steady load with throttle open, and O2 Controller not at or near its limits.
Set Condition: If all conditions met, turn EGR off & on. O2 Snsr Sig is monitored for
change in output sig. If no major change or too much change, flag is set. Repeat test up to
3x in run cycle (2 trips). If fails every time, code sets. If any pass, diags are suspended.
POSSIBLE CAUSES
EXHAUST LEAK
INTAKE MANIFOLD RESTRICTED
EGR BACK PRESSURE TRANSDUCER DEFECTIVE
EGR VALVE ASSEMBLY DEFECTIVE
EGR VALVE ASSEMBLY MOUNTED INCORRECTLY
EGR SYSTEM FAILURE DOES NOT REOCCUR
EGR TRANSDUCER LINE BLOCKED
EGR VALVE ASSEMBLY DIAPHRAM DEFECTIVE
VACUUM SUPPLY TO EGR SOLENOID INADEQUATE
TEST ACTION APPLICABILITY
1 With the DRB, read the DTCs.
Is the GLOBAL GOOD TRIP displayed and equal to zero?All
Ye s®Go To 3
No®Go To 2
2 At this time the EGR System Failure does not exist or is an intermittent problem.
With the DRB, read the FREEZE FRAME.
With this screen, 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 EGR System Failure reoccur?All
Ye s®Go To 3
No®EGR System Failure no longer exists.
Perform VERIFICATION TEST VER-5A3.
131
DRIVEABILITY
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Symptom:
P-1494 LEAK DETECTION PUMP PRESSURE SWITCH
When Monitored and Set Condition:
P-1494 LEAK DETECTION PUMP PRESSURE SWITCH
When Monitored: Immediately after a cold start, with ambient temperature between 4
deg C (40 deg F) and 32 deg C (90 deg F) and coolant temperature within ±12 deg C (10 deg
F) of ambient temperature.
Set Condition: The state of the switch does not change when the solenoid is energized.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
LDP PRESSURE SWITCH CIRCUIT SHORTED TO GROUND
LDP SWITCH SENSE CIRCUIT OPEN
LDP DEFECTIVE
LDP WIRING HARNESS INTERMITTENT DEFECT
LDP WIRING HARNESS OBSERVABLE DEFECT
LDP VACUUM HOSE LEAKING OR OBSTRUCTED
PCM DEFECTIVE
TEST ACTION APPLICABILITY
1 Start the engine and allow the engine to idle.
With the DRB, perform the Leak Detect Pump Test.
Select 1 to Pump.
Press the down arrow on the DRB several times.
The LEAK DETECT PUMP SW state should change from Open (UP) to CLOSED
(DN).
Did the Leak Detect Pump Switch state change as described?All
Ye s®Go To 2
No®Go To 4
206
DRIVEABILITY
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TEST ACTION APPLICABILITY
5 Engine Running
Disconnect the EGR Valve Hose from the EGR Valve.
Connect the vacuum gauge to the disconnected EGR Valve Hose.
While watching the gauge, unplug EGR Solenoid Electrical Connector.
Is the Vacuum over 3 inches at this time?All
Ye s®Test Complete.
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
6 Ignition Off
Adjust a shop air source to 20 PSI and connect to Backpressure Tube at base of EGR
Valve.
While opening and closing the throttle, listen for a tone change.
Did the tone change?All
Ye s®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
No®Go To 7
7 Engine Running
Disconnect the EGR Valve Hose from the EGR Valve.
Connect the vacuum gauge to the disconnected EGR Valve Hose.
While watching the gauge, unplug EGR Solenoid Electrical Connector.
Is the Vacuum over 3 inches at this time?All
Ye s®Go To 8
No®Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
8 Ignition Off
Remove the EGR Valve Assembly and inspect passages from Valve to Intake
Manifold.
Were passages open between EGR Valve and intake?All
Ye s®Go To 9
No®Repair the EGR Passages as necessary.
Perform Verification Test VER-2A.
9 Ignition Off
If there are no potential causes remaining, the EGR Valve Assembly is assumed to be
defective.
View repair options.All
Repair
Replace the EGR Valve Assembly.
Perform Verification Test VER-2A.
10 Ignition Off
Disconnect the EGR Vacuum Supply Hose at the Intake Manifold.
Connect a vacuum gauge to the Intake Manifold Nipple.
Read the vacuum gauge at idle.
Was the vacuum above 109at idle?All
Ye s®Repair the restriction or leak in the vacuum line to EGR Solenoid.
Perform Verification Test VER-2A.
No®Go To 11
229
DRIVEABILITY
* CHECKING EGR SYSTEM ÐContinued
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TEST ACTION APPLICABILITY
3 Ignition On, Engine Not Running
Press the S/C ON/OFF button to select S/C ªON.º
With the DRB, monitor the Speed Control Switch inputs.
While observing display, press the Set Switch several times.
Does the DRB show the Set Switch pressed and released?All
Ye s®Go To 4
No®Replace the Speed Control On/Off/Set Switch.
Perform Powertrain Verification Test VER-4A.
4 Ignition On, Engine Not Running
With the DRB, monitor the Speed Control Switch inputs.
While observing display, press the Brake Pedal several times.
Does the DRB show Brake Switch Status change between pressed and released?All
Ye s®Go To 5
No®Refer to symptom SPEED CONTROL BRAKE SWITCH OUT-
PUT in the SPEED CONTROL category.
5 Ignition On, Engine Not Running
With the DRB, monitor the Speed Control Switch inputs.
While observing the display, move the Gear Selector to Drive.
Does the DRB show the Park/Neutral Switch in D/R?All
Ye s®Go To 6
No®Refer to symptom CHECKING PARK/NEUTRAL POS SWITCH
in the SPEED CONTROL category.
6 Ignition Off
Disconnect the Speed Control Servo Connector.
Note: Check connectors - Clean/repair as necessary.
Turn the Ignition on and the S/C on.
Using a Voltmeter measure voltage of the S/C Brake Switch Output Ckt at Servo
Conn.
Is the voltage above 10 volts?All
Ye s®Go To 7
No®Go To 14
7 Ignition Off
Start engine, allow to idle 1 minute.
Turn Engine off, (Ignition on).
With the DRB, actuate the Speed Control Servo Solenoids.
Does the Throttle open and close?All
Ye s®Refer to symptom SPEED CONTROL DENIED MESSAGE in the
SPEED CONTROL category.
No®Go To 8
8 Ignition Off
Inspect the Speed Control Throttle Cable.
Is the Cable disconnected or damaged?All
Ye s®Repair as necessary.
Perform Powertrain Verification Test VER-4A.
No®Go To 9
267
SPEED CONTROL
* CHECKING SPEED CONTROL OPERATION ÐContinued
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