2001 CHRYSLER VOYAGER Service Manual

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Page 3777 of 4284

CHRYSLER VOYAGER 2001 Service Manual EMISSIONS CONTROL 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL 2.5L TURBO DIESEL
DESCRIPTION............................1
SPECIFICATIONS.........................2EXHAUST GAS RECIRCU

EMISSIONS CONTROL 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL 2.5L TURBO DIESEL
DESCRIPTION............................1
SPECIFICATIONS.........................2EXHAUST GAS RECIRCULATION.............3
ON-BOARD DIAGNOSTICS..................6
EMISSIONS CONTROL 2.5L
TURBO DIESEL
DESCRIPTION
The 2.5L diesel Engine Control Module (ECM) con-
trols many different circuits in the fuel injection
pump and engine systems. If the ECM senses a prob-
lem with a monitored circuit that indicates an actual
problem, a Diagnostic Trouble Code (DTC) will be
stored in the ECM's memory, and eventually may
illuminate the MIL (Malfunction Indicator Lamp)
constantly while the key is on. If the problem is
repaired, or is intermittent, the ECM will erase the
DTC after 40 warm-up cycles without the the fault
detected. A warm-up cycle consists of starting the
vehicle when the engine is cold, then the engine is
warmed up to a certain temperature, and finally, the
engine temperature falls to a normal operating tem-
perature, then the key is turned off.
Certain criteria must be met for a DTC to be
entered into ECM memory. The criteria may be a
specific range of engine rpm, engine or fuel tempera-
ture and/or input voltage to the ECM. A DTC indi-
cates that the ECM has identified an abnormal
signal in a circuit or the system.
There are several operating conditions that the
ECM does not monitor and set a DTC for. Refer to
the following Monitored Circuits and Non±Monitored
Circuits in this section.
ECM MONITORED SYSTEMS
The ECM can detect certain problems in the elec-
trical system.
Open or Shorted Circuit± The ECM will not
distinguish between an open or a short to ground,
however the ECM can determine if there is excessive
current on a circuit, such as a short to voltage or a
decrease in component resistance.
Output Device Current Flow± The ECM senses
whether the output devices are electrically connected.
If there is a problem with the circuit, the ECM
senses whether the circuit is open, shorted to ground
(±), or shorted to (+) voltage.Fuel Pressure:Fuel pressure is controlled by the
fuel injection pump and fuel pressure solenoid. The
ECM uses a fuel pressure sensor to determine if a
fuel pressure problem exists.
Fuel Injector Malfunctions:The ECM can deter-
mine if a fuel injector has an electrical problem. The
fuel injectors on the diesel engine arecontrolledby
the ECM.
ECM NON±MONITORED SYSTEMS
The ECM does not monitor the following circuits,
systems or conditions that could have malfunctions
that result in driveability problems. A DTC will not
be displayed for these conditions.
Cylinder Compression:The ECM cannot detect
uneven, low, or high engine cylinder compression.
Exhaust System:The ECM cannot detect a
plugged, restricted or leaking exhaust system.
Vacuum Assist:Leaks or restrictions in the vac-
uum circuits of the Exhaust Gas Recirculation Sys-
tem (EGR) are not monitored by the ECM.
ECM System Ground:The ECM cannot deter-
mine a poor system ground. However, a DTC may be
generated as a result of this condition.
ECM/PCM Connector Engagement:The ECM
cannot determine spread or damaged connector pins.
However, a DTC may be generated as a result of this
condition.
HIGH AND LOW LIMITS
The ECM compares input signals from each input
device. It has high and low limits that are pro-
grammed into it for that device. If the inputs are not
within specifications and other DTC criteria are met,
a DTC will be stored in memory. Other DTC criteria
might include engine rpm limits or input voltages
from other sensors or switches. The other inputs
might have to be sensed by the ECM when it senses
a high or low input voltage from the control system
device in question.
RGEMISSIONS CONTROL 2.5L TURBO DIESEL25a-1

Page 3778 of 4284

CHRYSLER VOYAGER 2001 Service Manual SPECIFICATIONS
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
EGR Valve Nuts 32.4 24 Ð
EGR Cooler to EGR Bolts 32.4 24 Ð
25a - 2 EMISSIONS CONTROL 2.5

Page 3779 of 4284

CHRYSLER VOYAGER 2001 Service Manual EXHAUST GAS RECIRCULATION
TABLE OF CONTENTS
page page
EXHAUST GAS RECIRCULATION
DESCRIPTION............................3
OPERATION.............................3
VA LV E
DESCRIPTION....................

EXHAUST GAS RECIRCULATION
TABLE OF CONTENTS
page page
EXHAUST GAS RECIRCULATION
DESCRIPTION............................3
OPERATION.............................3
VA LV E
DESCRIPTION............................3
OPERATION.............................4REMOVAL...............................4
INSTALLATION............................4
VALVE COOLER
DESCRIPTION............................4
REMOVAL...............................4
INSTALLATION............................5
EXHAUST GAS
RECIRCULATION
DESCRIPTION
The EGR system reduces oxides of nitrogen (NOx)
in the engine exhaust. This is accomplished by allow-
ing a predetermined amount of hot exhaust gas to
recirculate and dilute the incoming fuel/air mixture.
A malfunctioning EGR system can cause engine
stumble, sags, or hesitation, rough idle, engine stall-
ing and poor driveability.
OPERATION
The system consists of:
²An EGR valve assembly. The valve is located on
the rear of the engine above the exhaust manfiold.
²An EGR solenoid.The EGR solenoid controls the
ªon timeº of the EGR valve.
²The ECM operates the EGR solenoid. The ECM
is located inside the vehicle under the instrument
panel.
²An EGR tube connects a passage in the EGR
valve to the rear of the exhaust manifold.
²The vacuum pump supplies vacuum for the EGR
solenoid and the EGR valve. This pump also supplies
vacuum for operation of the power brake boosterb
and the heating and air conditioning system. The
pump is located internally in the front of the engine
block and is driven by the crankshaft gear.
²Vacuum lines and hoses connect the various
components.
When the ECM supplies a variable ground signal
to the EGR solenoid, EGR system operation starts to
occur. The ECM will monitor and determine when tosupply and remove this variable ground signal. This
will depend on inputs from the engine coolant tem-
perature, throttle position and engine speed sensors.
When the variable ground signal is supplied to the
EGR solenoid, vacuum from the vacuum pump will
be allowed to pass through the EGR solenoid and on
to the EGR valve with a connecting hose.
Exhaust gas recirculation will begin in this order
when:
²The ECM determines that EGR system opera-
tion is necessary.
²The engine is running to operate the vacuum
pump.
²A variable ground signal is supplied to the EGR
solenoid.
²Variable vacuum passes through the EGR sole-
noid to the EGR valve.
²The inlet seat (poppet valve) at the bottom of
the EGR valve opens to dilute and recirculate
exhaust gas back into the intake manifold.
The EGR system will be shut down by the ECM
after 60 seconds of continuous engine idling to
improve idle quality.
VA LV E
DESCRIPTION
The EGR system consists of (Fig. 1):
²EGR valve
²EGR tube
²Vacuum hoses
²EGR cooler
²EGR solenoid
RGEXHAUST GAS RECIRCULATION25a-3

Page 3780 of 4284

CHRYSLER VOYAGER 2001 Service Manual OPERATION
The engines use Exhaust Gas Recirculation (EGR)
systems. The EGR system reduces oxides of nitrogen
(NOx) in engine exhaust and helps prevent detona-
tion (engine knock). Under normal operati

OPERATION
The engines use Exhaust Gas Recirculation (EGR)
systems. The EGR system reduces oxides of nitrogen
(NOx) in engine exhaust and helps prevent detona-
tion (engine knock). Under normal operating condi-tions, engine cylinder temperature can reach more
than 3000ÉF. Formation of NOx increases proportion-
ally with combustion temperature. To reduce the
emission of these oxides, the cylinder temperature
must be lowered. The system allows a predetermined
amount of hot exhaust gas to recirculate and dilute
the incoming air/fuel mixture. The diluted air/fuel
mixture reduces peak flame temperature during com-
bustion.
REMOVAL
(1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Disconnect EGR valve vacuum line.
(4) Remove EGR cooler to EGR valve retaining
bolts (Fig. 1).
(5) Remove EGR valve retaining nuts (Fig. 1) and
EGR valve.
INSTALLATION
(1) Clean gasket mating surfaces.
(2) Install EGR valve (Fig. 1). Torque nuts to
32.4N´m.
(3) Connect EGR cooler to EGR valve (Fig. 1).
Torque bolts to 32.4N´m
(4) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(5) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION) .
VALVE COOLER
DESCRIPTION
The EGR valve on this engine uses a cooler to cool
the exhaust gases before the returned to the intake
manifold (Fig. 2). The EGR cooler attaches to the
EGR valve and is cooled with engine coolant.
REMOVAL
(1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(3) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL) .
(4) Disconnect coolant supply and return lines at
EGR cooler (Fig. 2).
(5) Remove EGR cooler to exhaust manifold retain-
ing bolt (Fig. 2).
Fig. 1 EGR COMPONENTS
1 - HOSE CLAMP
2 - COOLANT HOSE
3 - HOSE CLAMP
4 - EGR VALVE RETAINING NUT
5 - E G R VA LV E
6 - COOLANT HOSE
7 - EGR VALVE GASKET
8 - EGR VALVE RETAINING STUDS
9 - EGR COOLER RETAINING BOLT
10 - HOSE CLAMP
11 - HOSE CLAMP
12 - EGR COOLER
13 - EGR COOLER TO EGR VALVE RETAINING BOLT
14 - TURBOCHARGER BRACKET
15 - TURBOCHARGER BRACKET RETAINING BOLT
16 - TURBOCHARGER DOWNPIPE
17 - TURBOCHARGER DOWNPIPE RETAINING NUT
18 - DOWNPIPE GASKET
19 - DOWNPIPE STUD
25a - 4 EXHAUST GAS RECIRCULATIONRG
VALVE (Continued)

Page 3781 of 4284

CHRYSLER VOYAGER 2001 Service Manual (6) Remove EGR cooler to EGR valve retaining
bolts (Fig. 2) and remove cooler.
INSTALLATION
(1) Clean gasket sealing surfaces.
(2) Connect EGR valve cooler and new gasket to
EGR valve (Fig. 2). Torque

Page 3782 of 4284

CHRYSLER VOYAGER 2001 Service Manual ON-BOARD DIAGNOSTICS
TABLE OF CONTENTS
page
ON-BOARD DIAGNOSTICS
DESCRIPTION............................6
ON-BOARD DIAGNOSTICS
DESCRIPTION - DIAGNOSTIC TROUBLE CODES
On the following pages, a list of

Page 3783 of 4284

CHRYSLER VOYAGER 2001 Service Manual Generic Scan Tool Code DRB IIITScan Tool Display
P0115 Engine Coolant Temperature Sensor Circuit Engine Is Cold Too Long
Engine Coolant Temperature Sensor Circuit Voltage To Low
Engine Coolant Tempera

Page 3784 of 4284

CHRYSLER VOYAGER 2001 Service Manual Generic Scan Tool Code DRB IIITScan Tool Display
P0403 EGR Solenoid Circuit Open Circuit
EGR Solenoid Circuit Short Circuit
P0480 Fan 1 Control Circuit Open Circuit
Fan 1 Control Circuit Short Circuit

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