2001 CHRYSLER VOYAGER ignition

Symptom:
P1602-PCM NOT PROGRAMMED
When Monitored and Set Condition:
P1602-PCM NOT PROGRAMMED
When Monitored: Ignition key on.
Set Condition: PCM has not been programmed.
POSSIBLE CAUSES
PCM PROGRAMMED
TEST ACTION APPLICABILITY
1 Attempt to program PCM in accordance with the Service Information.
Turn the ignition on.
Start the engine.
NOTE: If the engine will not start, crank the engine over for 15 seconds.
Crank at least 2 time with the ignition switch returning to the off position
each time.
Allow the engine to reach normal operating temperature.
With the DRBIIIt, read DTCs.
Does the DTC reset?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Test Complete.
221
DRIVEABILITY - GAS

Symptom:
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (3SP AUTO
TRANS)
When Monitored and Set Condition:
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (3SP AUTO TRANS)
When Monitored: Continuously with the transmission in Park, Neutral, or Drive and
NOT in Limp-in mode.
Set Condition: This code will set if the PCM detects an incorrect Park/Neutral switch
state for a given mode of vehicle operation. Two trip fault.
POSSIBLE CAUSES
INTERMITTENT PARK/NEUTRAL SWITCH
P/N POSITION SWITCH SENSE CIRCUIT SHORTED TO GROUND
P/N POSITION SWITCH SENSE CIRCUIT OPEN
PARK/NEUTRAL POSITION SWITCH
POWERTRAIN CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read PCM DTCs.
Is the Good Trip displayed and equal to zero?All
Ye s®Go To 2
No®Go To 7
2 Turn the ignition on.
With the DRBIIIt, read the Park/Neutral Position Switch input state.
While moving the gear selector through all gear positions (Park to 1 and back to
Park), monitor the DRB display.
Did the DRB display show P/N and D/R in the correct gear positions?All
Ye s®Go To 7
No®Go To 3
3 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Park/Neutral Position Switch harness connector.
Measure the resistance between ground and the P/N Position Switch Sense circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 4
No®Repair the P/N Position Switch Sense circuit for a short to ground.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
222
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Park/Neutral Position Switch harness connector.
Measure the resistance of the P/N Position Switch Sense circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the P/N Position Switch Sense circuit for an open.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
5 Turn the ignition off.
Disconnect the PCM harness connector.
Move the Gear selector through all gear positions, from Park to 1st and back.
While moving the gear selector through each gear, measure the resistance between
ground and the P/N Position Switch Sense circuit.
Did the resistance change from above 10.0 ohms to below 10.0 ohms?All
Ye s®Go To 6
No®Replace the Park/Neutral Position Switch.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Module in accordance with
the Service Information.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER 1..
7 At this time, the conditions required to set the DTC are not present.
NOTE: Use the Freeze Frame Data to help duplicate the conditions that set
the DTC. Pay particular attention to the DTC set conditions, such as, VSS,
MAP, ECT, and Load.
NOTE: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Visually inspect the related wiring harness connectors. Look for
broken, bent, pushed out, or corroded terminals.
NOTE: Refer to any technical service bulletins (TSB) that may apply.
Were any problems found?All
Ye s®Repair as necessary.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
No®Test Complete.
223
DRIVEABILITY - GAS
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (3SP AUTO TRANS) Ð
Continued

Symptom:
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (4SP AUTO
TRNAS)
When Monitored and Set Condition:
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (4SP AUTO TRNAS)
When Monitored: Continuously with the transmission in Park, Neutral, or Drive and
NOT in Limp-in mode.
Set Condition: This code will set if the PCM detects an incorrect Park/Neutral switch
state for a given mode of vehicle operation. Two trip fault.
POSSIBLE CAUSES
INTERMITTENT PARK/NEUTRAL SWITCH
P/N POSITION SWITCH SENSE CIRCUIT SHORTED TO GROUND
P/N POSITION SWITCH SENSE CIRCUIT OPEN
TRANSMISSION RANGE SENSOR
POWERTRAIN CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read PCM DTCs.
Is the Good Trip displayed and equal to zero?All
Ye s®Go To 2
No®Go To 7
2 Turn the ignition on.
With the DRBIIIt, read the Park/Neutral Position Switch input state.
While moving the gear selector through all gear positions (Park to 1 and back to
Park), monitor the DRB display.
Did the DRB display show P/N and D/R in the correct gear positions?All
Ye s®Go To 7
No®Go To 3
3 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Transmission Range Sensor harness connector.
Measure the resistance between ground and the P/N Position Switch Sense circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 4
No®Repair the P/N Position Switch Sense circuit for a short to ground.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1..
224
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Transmission Range Sensor harness connector.
Measure the resistance of the P/N Position Switch Sense circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the P/N Position Switch Sense circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1..
5 Turn the ignition off.
Disconnect the PCM harness connector.
Move the Gear selector through all gear positions, from Park to 1st and back.
While moving the gear selector through each gear, measure the resistance between
ground and the P/N Position Switch Sense circuit.
Did the resistance change from above 10.0 ohms to below 10.0 ohms?All
Ye s®Go To 6
No®Replace the Transmission Range Sensor.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1..
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Module in accordance with
the Service Information.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1..
7 At this time, the conditions required to set the DTC are not present.
NOTE: Use the Freeze Frame Data to help duplicate the conditions that set
the DTC. Pay particular attention to the DTC set conditions, such as, VSS,
MAP, ECT, and Load.
NOTE: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Visually inspect the related wiring harness connectors. Look for
broken, bent, pushed out, or corroded terminals.
NOTE: Refer to any technical service bulletins (TSB) that may apply.
Were any problems found?All
Ye s®Repair as necessary.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1..
No®Test Complete.
225
DRIVEABILITY - GAS
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (4SP AUTO TRNAS) Ð
Continued

Symptom:
*CHECKING ECT SENSOR
POSSIBLE CAUSES
ECT SENSOR OPERATION
ECT SENSOR
TEST ACTION APPLICABILITY
1NOTE: The engine coolant temperature must be below 62ÉC (150ÉF).
Turn the ignition on.
With the DRBIIIt, monitor the ECT value.
Start the engine.
Does the ECT reach 82ÉC (180ÉF) and was it a smooth transition?All
Ye s®Engine Coolant Temperature sensor is operating normally.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Replace the Engine Coolant Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
226
DRIVEABILITY - GAS

Symptom:
*CHECKING FUEL DELIVERY
POSSIBLE CAUSES
FUEL PUMP RELAY
FUEL PRESSURE OUT OF SPECS
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
FUEL PUMP CAPACITY (VOLUME) OUT OF SPECS
FUEL PUMP RELAY FUSED B+ CIRCUIT
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN/HIGH RESISTANCE
IPM FUSE & RELAY CENTER
FUEL PUMP MODULE
TEST ACTION APPLICABILITY
1NOTE: Inspect the Fuel Pump Relay fuse located in the IPM. If the Fuel
Pump Relay fuse is open, repair the cause of the open first before continu-
ing. Inspect the Fuel Pump Relay Output circuit for a short to ground for
the cause of the open fuse.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Note: It may be necessary to use a mechanics stethoscope in the next step.
Listen for fuel pump operation at the fuel tank.
Does the Fuel Pump operate?All
Ye s®Go To 2
No®Go To 6
Caution: Stop All Actuations.
227
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
2 Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install a fuel pressure gauge to the fuel rail test port.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.All
Below Specification
Go To 3
Within Specification
Go To 5
Above Specification
Replace the fuel filter/fuel pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER-1.
Caution: Stop All Actuations.
3 Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/169fuel line adapter tool #6539 between disconnected fuel line and
the fuel pump module.
Attach a fuel pressure test gauge to the9T9fitting on tool #6539.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Is the fuel pressure within specification now?All
Ye s®Repair/replace fuel supply line as necessary.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Go To 4
Caution: Stop All Actuations.
4 Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose,fitting or line,
the fuel system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?All
Ye s®Replace the Fuel Pump Inlet Strainer.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
228
DRIVEABILITY - GAS
*CHECKING FUEL DELIVERY ÐContinued