2001 CHRYSLER VOYAGER fuel pump

TEST ACTION APPLICABILITY
5 Turn the ignition off.
Disconnect the Fuel Pressure Solenoid harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Fuel Pressure Solenoid Control circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Fuel Pressure Solenoid Control circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Disconnect the Fuel Pressure Solenoid harness connector.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Monitor the DRB for ECM DTCs.
NOTE: The DRB should display P1131-FUEL PRESSURE SOLENOID OPEN
CIRCUIT.
Turn the ignition off.
Connect a jumper wire between cavity 1 and cavity 2 of the Fuel Pressure Solenoid
harness connector.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Monitor the DRB for ECM DTCs.
NOTE: The DRB should display P1131-FUEL PRESSURE SOLENOID
SHORT CIRCUIT.
Does the DRB display the appropriate DTC for each condition?All
Ye s®Replace the Fuel Pressure Solenoid/Fuel Pump Assembly in
accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 7
7 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
160
DRIVEABILITY - DIESEL
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT ÐContinued

Symptom:
*CHECKING THE ENGINE MECHANICAL SYSTEMS
POSSIBLE CAUSES
CHECKING ENGINE MECHANICAL SYSTEMS
TEST ACTION APPLICABILITY
1NOTE: The following items should be checked as a possible cause of a
Driveability or No-Start problem.
WARNING: Do not attempt to remove or separate high pressure fuel line.
Attempting to do so could result in severe bodily injury or death.
Engine Valve Timing - must be within specification
Engine Compression - must be within specifications
Camshaft Lobes - check for abnormal wear
Camshaft Position Sensor - check the camshaft position sensor tooth for debris and
deterioration
Crankshaft Position Sensor - check the crankshaft tone wheel for debris and
deterioration
Engine Exhaust System - must be free of any restriction
Engine Drive Sprocket - must be properly positioned
Power Brake Booster - must be free of any vacuum leaks
Fuel - must have adequate supply and must be free of contamination and gasoline
Fuel Injectors - must not be plugged or restricted
Fuel Injection Pump - must be producing the correct output volume and pressure
Inspect the Fuel Lines, Fuel Filter and Fuel Pressure Relief Valve for signs of
restriction and leaks
NOTE: Check for any Technical Service Bulletins that may relate to the
problem.
Are there any problems evident?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
194
DRIVEABILITY - DIESEL

Symptom:
*CHECKING THE LIFT PUMP MOTOR OPERATION
POSSIBLE CAUSES
LIFT PUMP OUTPUT TEST
FUSED B+ CIRCUIT OPEN
LIFT PUMP RELAY
LIFT PUMP RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
LIFT PUMP RELAY OUTPUT CIRCUIT SHORTED TO GROUND
LIFT PUMP RELAY OUTPUT CIRCUIT OPEN
LIFT PUMP GROUND CIRCUIT OPEN
LIFT PUMP MOTOR
TEST ACTION APPLICABILITY
1NOTE: If any Fuel Lift Pump DTCs are present, diagnose the DTCs first.
Turn the ignition on.
With the DRB, actuate the Lift Pump Relay.
Gain access to the Lift Pump Motor to determine if it is cycling on and off.
Does the Lift Pump Motor cycle on and off?All
Ye s®Go To 2
No®Go To 3
2NOTE: The Lift Pump fuel output must be sufficient to prime the Injector
Pump.
Refer to the Service Information to test the Lift Pump pressure and volume output.
Did the Lift Pump pass the Lift Pump pressure and volume test?All
Ye s®Test Complete.
No®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
3NOTE: If the Lift Pump Relay fuse is open, refer to the system schematics
for all circuits that are powered by the Lift Pump Relay fuse to determine
the cause of the blown fuse.
Remove the Lift Pump Relay from the IPM.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the Lift
Pump Relay connector in the IPM.
Does the test light illuminate brightly?All
Ye s®Go To 4
No®Repair the Fused B+ (Fuse) circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
197
DRIVEABILITY - DIESEL

ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAYCAV CIRCUIT FUNCTION
51 - -
52 K121 20DB BOOST PRESSURE SENSOR GROUND
53 - -
54 K957 20BK/OR MASS AIR FLOW SENSOR GROUND
55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 - -
58 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND
59 - -
60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20BR/WT ECM/PCM RELAY CONTROL
62 - -
63 D21 20WT/BR SCI TRANSMIT
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
67 - -
68 - -
69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
71 - -
72 N21 20DB/TN LIFT PUMP RELAY CONTROL
73 - -
74 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
75 - -
76 - -
77 K152 20DB/WT GLOW PLUG RELAY CONTROL
78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
79 - -
80 K87 20BR FUEL PRESSURE SOLENOID CONTROL
81 K87 20BR FUEL PRESSURE SOLENOID CONTROL
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CONNECTOR PINOUTS

A/C COMPRESSOR CLUTCH RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 C13 18LB/OR (GAS) A/C COMPRESSOR CLUTCH RELAY CONTROL
85 C13 20LB/OR (DIESEL) A/C COMPRESSOR CLUTCH RELAY CONTROL
86 F202 18PK/GY (GAS) IGNITION SWITCH OUTPUT (RUN-START)
86 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
87 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
87A --
ECM/PCM RELAY (DIESEL)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K51 20BR/WT ECM/PCM RELAY CONTROL
86 INTERNAL FUSED B(+)
87 K342 16BR/WT ECM/PCM RELAY OUTPUT
87A --
FUEL HEATER RELAY (DIESEL)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 Z114 18BK/LG GROUND
86 INTERNAL IGNITION SWITCH OUTPUT (RUN-START)
87 N1 16DB/OR FUEL HEATER RELAY OUTPUT
87A --
LIFT PUMP RELAY (DIESEL)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 N21 20DB/TN LIFT PUMP RELAY CONTROL
86 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
87 N2 18DB/YL LIFT PUMP RELAY OUTPUT
87A --
STARTER MOTOR RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 T752 18DG/OR (GAS) ENGINE STARTER MOTOR RELAY CONTROL
85 T752 20DG/OR (DIESEL) ENGINE STARTER MOTOR RELAY CONTROL
86 INTERNAL IGNITION SWITCH OUTPUT (START)
87 T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT
87A --
RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAYCAV CIRCUIT FUNCTION
1 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
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CONNECTOR PINOUTS

Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as ªreformulat-
edº gasoline. Reformulated gasoline contain oxygen-
ates, and are specifically blended to reduce vehicle
emissions and improve air quality.
We strongly supports the use of reformulated gas-
oline. Properly blended reformulated gasoline will
provide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasolines free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting Californiaemission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may be
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle's catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle's performance:
²The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
²The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of Daimler-
Chrysler Corporation and may not be covered under
the new vehicle warranty.
RSLUBRICATION & MAINTENANCE0-5
FLUID TYPES (Continued)

²Inspect the generator belt on 2.4 liter engines
and replace if necessary.
²Inspect the serpentine drive belt on 3.3 liter and
3.8 liter engines. Not required if replaced at 75,000,
90,000 or 105,000 miles.
²Replace theengine timing belton 2.4 liter
engine only.
²Inspect the tie rod ends and boot seals.
* This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
SCHEDULE±B±DODGE VEHICLES, CHRYSLER
VOYAGER
Follow this schedule if the vehicle is usually oper-
ates under one or more of the following conditions.
²Frequent short trips of less than 5 miles
²Frequent driving in dusty conditions
²Frequent trailer towing
²Day and night temperatures are below freezing
²Frequent stop and go driving
²Extensive periods of idling
²Frequent operation at sustained high speeds
during hot weather, above 90ÉF (32ÉC)
²Use of E-85 (ethanol) fuel in 3.3 liter engines.
3,000 Miles (5 000 km)
²Change the engine oil.
²Replace the engine oil filter.
6,000 Miles (10 000 km)
²Change the engine oil.
²Replace the engine oil filter.
9,000 Miles (14 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
12,000 Miles (19 000 km)
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect theengine air cleaner element (fil-
ter).Replace as necessary.*
²Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule ±
B.)
²Inspect the generator belt on 2.4 liter engines
and replace if necessary.
18,000 Miles (29 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
21,000 Miles (34 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end
of Schedule ± B.)
24,000 Miles (38 000 km)
²Change the engine oil.
²Replace the engine oil filter.
27,000 Miles (43 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
30,000 Miles (48 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Replace theengine air cleaner element (fil-
ter).
²Inspect thePCV valveand replace as neces-
sary.*
²Replace thespark plugs2.4 liter engines.
²Inspect and adjust the generator belt and power
steering pump belt tension on 2.4 liter engines.
²Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule ±
B.)
²Inspect the tie rod ends and boot seals.
33,000 Miles (53 000 km)
²Change the engine oil.
²Replace the engine oil filter.
36,000 Miles (58 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
39,000 Miles (62 000 km)
²Change the engine oil.
²Replace the engine oil filter.
42,000 Miles (67 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end
of Schedule ± B.)
RSLUBRICATION & MAINTENANCE0-13
MAINTENANCE SCHEDULES (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Excessive Steering Free
Play1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specified
torque
4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive
belt4. Correctly adjust power steering pump
drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering coupler 7. Replace steering coupler
STANDARD PROCEDURE - WHEEL ALIGNMENT
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct
the wheel alignment, the following inspection and
necessary corrections must be made to ensure proper
alignment.
(1) Verify that the fuel tank is full of fuel. If the
tank is not full, the reduction in weight will affect
the curb height of the vehicle and the alignment
angles.
(2) The passenger and luggage compartments of
the vehicle should be free of any load that is not fac-
tory equipment.
(3) Check the tires on the vehicle. All tires must be
the same size and in good condition with approxi-
mately the same amount of tread wear. Inflate all
the tires to the recommended air pressure.
(4) Check the front wheel and tire assemblies for
excessive radial runout.
(5) Inspect lower ball joints and all steering link-
age for looseness, binding, wear or damage. Repair as
necessary.
(6) Check suspension fasteners for proper torque
and retighten as necessary.
(7) Inspect all suspension component rubber bush-
ings for signs of wear or deterioration. Replace any
faulty bushings or components before aligning the
vehicle.
(8) Check the vehicle's curb height to verify it is
within specifications. Refer to Curb Height Measure-
ment.
WHEEL ALIGNMENT SETUP
(1) Position the vehicle on an alignment rack.
(2) Install all required alignment equipment on
the vehicle per the alignment equipment manufactur-
er's instructions. On this vehicle, a four-wheel align-
ment is recommended.
NOTE: Prior to reading the vehicle's alignment
readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by
grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The
bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Read the vehicle's current front and rear align-
ment settings. Compare the vehicle's current align-
ment settings to the vehicle specifications for camber,
caster and toe-in. (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - SPECIFICATIONS)
(4) If front camber and caster are not within spec-
ifications, proceed to CAMBER AND CASTER below.
If caster and camber are within specifications, pro-
ceed to TOE which can be found following CAMBER
AND CASTER. Rear camber, caster and toe are not
adjustable. If found not to be within specifications,
reinspect for damaged suspension or body compo-
nents and replace as necessary.
CAMBER AND CASTER
Camber and caster settings on this vehicle are
determined at the time the vehicle is designed, by
the location of the vehicle's suspension components.
This is referred to as NET BUILD. The result is no
RSWHEEL ALIGNMENT2-51
WHEEL ALIGNMENT (Continued)