2001 CHRYSLER VOYAGER ignition

TEST ACTION APPLICABILITY
1NOTE: Record the Freeze Frame Information that set along with the DTC.
Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the Good Trip displayed and equal to zero?All
Ye s®Go To 2
No®Go To 7
2 Turn the ignition off.
Disconnect the Ignition Coil harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Relay.
Using a 12 volt test light connected to ground, probe the ASD Relay Output circuit in
the Ignition Coil harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Repair the ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
3 Turn the ignition off.
Disconnect the Ignition Coil harness connector.
Using a 12-volt test light connected to 12-volts, probe the Ignition Coil Driver circuit.
Crank the engine for 5 second while observing the test light.
Does the test light blink/flicker?All
Ye s®Replace the Ignition Coil.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 4
4 Turn the ignition off.
Disconnect the Ignition Coil harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Ignition Coil driver circuit between the Ignition Coil
harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the Ignition Coil driver circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5 Turn the ignition off.
Disconnect the Ignition Coil harness connector.
Disconnect the PCM harness connector.
Measure the resistance between ground and the Ignition Coil driver circuit in the
Ignition Coil harness connector.
Is the resistance below 100k ohms?All
Ye s®Repair the Ignition Coil driver circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 6
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DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DRB Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
123
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT ÐContinued

Symptom:
P0401 - EGR SYSTEM FAILURE
When Monitored and Set Condition:
P0401 - EGR SYSTEM FAILURE
When Monitored: With the ignition on and the battery voltage greater than 10.4 volts.
Set Condition: Conditions are met, the EGR is turned off and on momentarily. The
oxygen sensor signal is monitor for changes in its output signal during this test. If no
significant change or too much change is seen, a flag is set.
POSSIBLE CAUSES
INTERMITTENT CONDITION
EGR SOLENOID VACUUM SUPPLY
EGR VALVE OPERATION (CLOSED)
EGR VALVE OPERATION (OPEN)
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EGR SOLENOID CONTROL CKT SHORTED TO VOLTAGE
EGR SOLENOID CONTROL CKT OPEN
EGR SOLENOID (CLOSED)
EGR SOLENOID CONTROL CKT SHORT TO GND
EGR SOLENOID (OPEN)
PCM
PCM (CLOSED)
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the Good Trip displayed and equal to zero?All
Ye s®Go To 2
No®Go To 12
2 Start the engine.
Allow the engine to reach operating temperature.
Does the engine run rough or stall at idle?All
Ye s®Go To 3
No®Go To 6
124
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3 Disconnect the vacuum hose from the EGR Valve.
Start the engine and allow it to idle.
Does the engine run rough or stall at idle?All
Ye s®Remove the EGR Valve and inspect the valve for an obstruction
that would keep the valve open. If OK, replace the EGR Valve.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 4
4 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the EGR Solenoid Control circuit in the EGR Solenoid
harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the EGR Solenoid Control circuirt for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 5
5 Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Using a 12-volt test light connected to 12-volts, probe the EGR Solenoid Control
circuit.
Turn the ignition on.
With the DRBIIIt, actuate the EGR Solenoid.
Observe the test light.
Does the test light flash on and off?All
Ye s®Replace the EGR Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6 Turn the ignition off.
Disconnect the EGR Solenoid vacuum supply at the EGR Solenoid.
Connect a vacuum gauge to the EGR Solenoid vacuum supply.
Start the engine.
Observe the vacuum gauge.
Does the vacuum gauge read above 109?All
Ye s®Go To 7
No®Repair the EGR Solenoid vacuum supply.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7 Disconnect the vacuum hose from the EGR Valve.
Connect a Vacuum Pump to the EGR Valve.
Using the Vacuum Pump, apply vacuum to the EGR Valve.
Does the engine run rough or stall at idle?All
Ye s®Go To 8
No®Remove the EGR Valve and inspect the valve for an obstruction
that would keep the valve form opening. If OK, replace the EGR
Valve.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
125
DRIVEABILITY - GAS
P0401 - EGR SYSTEM FAILURE ÐContinued

TEST ACTION APPLICABILITY
8 Turn the igntion off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Using a 12 volt Test Light connected to ground, probe the Fused Ignition Switch
Output circuit in the EGR Solenoid harness connector.
Does the 12 volt test light illuminate?All
Ye s®Go To 9
No®Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9 Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Measure the voltage of the EGR Solenoid Control circuit in the EGR Solenoid
connector.
Is the voltage above 1.0 volts?All
Ye s®Repair the EGR Solenoid Control circuit for a short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 10
10 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the EGR Solenoid Control circuit between the PCM
harness connector and the EGR Solenoid harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 11
No®Repair the EGR solenoid control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
11 Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Using a 12-volt test light connected to 12-volts, probe the EGR Solenoid Control
circuit in the EGR Solenoid harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the EGR Solenoid.
Observe the test light.
Does the test light flash on and off.All
Ye s®Inspect the EGR Solenoid Back Pressure hose and tube for
obstructions or damage. If OK, replace the EGR Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
126
DRIVEABILITY - GAS
P0401 - EGR SYSTEM FAILURE ÐContinued

Symptom:
P0403 - EGR SOLENOID CIRCUIT
When Monitored and Set Condition:
P0403 - EGR SOLENOID CIRCUIT
When Monitored: Engine running. Battery voltage greater than 10 volts.
Set Condition: The EGR solenoid control circuit is not in the expected state when
requested to operate by the PCM.
POSSIBLE CAUSES
INTERMITTENT CONDITION
EGR SOLENOID
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EGR SOLENOID CONTROL CKT SHORTED TO VOLTAGE
EGR SOLENOID CONTROL CKT SHORT TO GND
EGR SOLENOID CONTROL CKT OPEN
PCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the Good Trip displayed and equal to zero?All
Ye s®Go To 2
No®Go To 8
2 Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Turn all accessories off.
Using a 12 volt Test Light connected to the Fused Ignition Switch Output circuit,
probe the EGR Solenoid Control circuit.
With the DRB, actuate the EGR solenoid.
Does the 12 volt test light flash on and off?All
Ye s®Inspect the EGR Valve Back Pressure hose and tube for obstruc-
tions or damage. If OK, replace the EGR Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
128
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3 Turn the igntion off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Using a 12 volt Test Light connected to ground, probe the Fused Ignition Switch
Output circuit in the EGR Solenoid harness connector.
Does the 12 volt test light illuminate?All
Ye s®Go To 4
No®Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4 Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Measure the voltage of the EGR Solenoid Control circuit in the EGR Solenoid
connector.
Is the voltage above 1.0 volt?All
Ye s®Repair the EGR Solenoid Control circuit for a short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 5
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the EGR Solenoid Control circuit in the EGR Solenoid
harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the EGR Solenoid Control circuirt for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 6
6 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the EGR Solenoid Control circuit between the PCM
harness connector and the EGR Solenoid harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the EGR Solenoid Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
129
DRIVEABILITY - GAS
P0403 - EGR SOLENOID CIRCUIT ÐContinued

Symptom:
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored and Set Condition:
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored: After engine warm up to 70ÉC (158ÉF), 180 seconds of open throttle
operation, at a speed greater than 18 mph and less than 55 mph, with the engine at
1200-1700 rpm and MAP vacuum between 15.0 and 21.0 inches of mercury (Hg).
Set Condition: As catalyst efficiency deteriorates, the switch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. If at any point during the test the
switch ratio reaches a predetermined value a counter is incremented by one.
POSSIBLE CAUSES
INTERMITTENT CONDITION
VISUALLY INSPECT CATALYTIC CONVERTER
EXHAUST LEAK
ENGINE MECHANICAL CONDITION
AGING O2 SENSOR
CATALYTIC CONVERTER
TEST ACTION APPLICABILITY
1NOTE: If a O2 Sensor DTC(s) set along with the Catalytic Converter
Efficiency DTC diagnose the O2 Sensor DTC(s) before continuing.
NOTE: Check for contaminates that may have damaged the O2 Sensor and
Catalytic Converter: contaminated fuel, unapproved silicone, oil and cool-
ant, repair necessary.
Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the Good Trip displayed and equal to zero?All
Ye s®Go To 2
No®Go To 7
2 Inspect the Catalytic Converter for the following damage.
Damage Catalytic Converter, dent and holes.
Severe discoloration caused by overheating the Catalytic Converter.
Catalytic Converter broke internally.
Leaking Catalytic Converter.
Were any problems found?All
Ye s®Replace the Catalytic Converter. Repair the condition that may
have caused the failure.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
131
DRIVEABILITY - GAS