2001 CHRYSLER VOYAGER check engine

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

TEST ACTION APPLICABILITY
5Note: The fuel pressure must be within specification before continuing.
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.
Disconnect the fuel supply line at the fuel rail.
Connect fuel line adapter #6539(5/169) or #6631(3/89) to the disconnected fuel supply
line. Insert the other end of the adapter into a graduated container.
Caution: Do not operate the fuel pump for more than 7 seconds in the next
step. Fuel pump module reservoir may run empty and damage to the fuel
pump will result.
Note: Specification: A good fuel pump will deliver at least 1/4 liter (1/2 pint)
of fuel in 7 seconds.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test for 7 seconds.
Is the fuel pump capacity within specification?All
Ye s®Test Complete.
No®Check for a kinked/damaged fuel supply line between the fuel
tank and fuel rail. If OK, replace the fuel pump module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
Caution: Stop All Actuations.
6 Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Using a 12 volt test light connected to ground, probe the Fuel Pump Relay Output
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 7
No®Go To 9
Caution: Stop All Actuations.
7 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Note: Check connectors - It is critical that the connector is free from any
signs of corrosion or deformities - Clean/repair as necessary.
Using a test light connected to battery voltage, probe the Fuel Pump ground circuit
at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 8
No®Repair the open/high resistance in the fuel pump ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
8 If there are no possible causes remaining, view repair. All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
229
DRIVEABILITY - GAS
*CHECKING FUEL DELIVERY ÐContinued

Symptom:
*CHECKING IAC MOTOR (2.4L)
POSSIBLE CAUSES
IAC MOTOR OPERATION
IAC DRIVER CIRCUITS OPEN
IAC MOTOR
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, monitor engine RPM.
With the DRBIIIt, set the engine speed to 1400 RPM.
Does the engine speed reach 1400 rpm?All
Ye s®The IAC Motor is operation normally
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Go To 2
2 Turn the ignition off.
Disconnect IAC Motor harness connector.
Disconnect the PCM harness connector.
Repeat each measurement for each IAC Driver circuit.
Measure the resistance of each IAC Driver circuit between the IAC Motor harness
connector and the PCM harness connector.
Is the resistance below 5.0 ohms at all IAC Driver circuits?All
Ye s®Replace the Idle Air Control Motor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Repair the IAC Driver circuit(s) for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
231
DRIVEABILITY - GAS

Symptom:
*CHECKING MAP SENSOR
POSSIBLE CAUSES
MAP SENSOR OPERATION
MAP SENSOR
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Attach a vacuum gauge to a manifold vacuum source.
NOTE: If the engine will not idle, maintain a constant engine speed above
idle.
Allow the engine to idle.
With the DRBIIIt, monitor the MAP sensor vacuum.
Compare the MAP vacuum value on the DRBIIItand the vacuum reading on the
vacuum gauge.
Are the vacuum readings within 1 inch of vacuum of each other?All
Ye s®The MAP sensor is operating normally.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Replace the MAP sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
233
DRIVEABILITY - GAS

Symptom:
*ENGINE CRANKS DOES NOT START
POSSIBLE CAUSES
FUEL PUMP RELAY
NO START PRE-TEST
POWERTRAIN FUSES OPEN
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
OTHER POSSIBLE CAUSES FOR NO START
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN/HIGH RESISTANCE
IPM FUSE & RELAY CENTER
FUEL PUMP MODULE
TEST ACTION APPLICABILITY
1Note: The following list of items must be checked before continuing with
any no start tests.
The battery must be fully charged and in good condition. A low charged battery may
produce invalid test results. If the battery is low, charge the battery and then attempt
to start the vehicle by cranking the engine for 15 seconds, 3 consecutive times.
This will allow any DTC's to set that may have been erased due to a dead battery.
Ensure the Powers and Ground to the PCM are ok.
Make sure the PCM communicates with the DRB and that there are no DTC's stored
in the PCM memory. If the PCM reports a No Response condition, refer to the
Communication category for the proper tests.
Read the PCM DTC's with the DRB. If any DTC's are present, they must be repaired
before continuing with any other No Start diagnostic tests. Refer to the Symptom list
for the related P-code that is reported by the PCM.
Ensure that the PCI bus is functional. Attempt to communicate with the Instrument
Cluster and SKIM, If you are unable to establish communicate refer to the
Communication category for the proper symptoms.
The Sentry Key Immobilizer System must be operating properly. Check for proper
communication with the DRB and check for DTC's that may be stored in the Sentry
Key Immobilizer Module (SKIM). repair the DTC(s) before continuing.
If no DTC's are found, using the DRB select Clear PCM (Batt Disconnect).
Crank the engine several times. Using the DRB, read DTC's. If a DTC is present
perform the DTC diagnostics before continuing.
Were any problems found?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Go To 2
253
STARTING

TEST ACTION APPLICABILITY
2 Check for any open fuses in the IPM that may be related to the No Start condition.
Are any of the fuses open?All
Ye s®Using the wiring diagram/schematic as a guide, inspect the
wiring and connectors, repair as necessary. Replace the Fuse.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Go To 3
3 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 4
No®Go To 9
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.
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 5
Within Specification
Go To 7
Above Specification
Replace the fuel filter/fuel pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER-1.
Caution: Stop All Actuations.
254
STARTING
*ENGINE CRANKS DOES NOT START ÐContinued

TEST ACTION APPLICABILITY
5 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 6
Caution: Stop All Actuations.
6 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.
7Note: The fuel pressure must be within specification before continuing.
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.
Disconnect the fuel supply line at the fuel rail.
Connect fuel line adapter #6539(5/169) or #6631(3/89) to the disconnected fuel supply
line. Insert the other end of the adapter into a graduated container.
Caution: Do not operate the fuel pump for more than 7 seconds in the next
step. Fuel pump module reservoir may run empty and damage to the fuel
pump will result.
Note: Specification: A good fuel pump will deliver at least 1/4 liter (1/2 pint)
of fuel in 7 seconds.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test for 7 seconds.
Is the fuel pump capacity within specification?All
Ye s®Go To 8
No®Check for a kinked/damaged fuel supply line between the fuel
tank and fuel rail. If OK, replace the fuel pump module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
Caution: Stop All Actuations.
255
STARTING
*ENGINE CRANKS DOES NOT START ÐContinued

TEST ACTION APPLICABILITY
8 The following items need to be checked as a possible cause for a no start condition.
Refer to any Technical Service Bulletins that may apply to the symptom.
The spark plugs must be free from fuel, oil, coolant and/or any foreign material or
deposits.
The fuel must be free from contamination.
The exhaust may be free from restrictions.
The engine compression must be within specifications.
The engine valve timing must be within specifications.
The engine must be free from vacuum leaks.
Were any of the above conditions found?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Test Complete.
9 Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Using a 12 volt test light connected to ground, probe the Fuel Pump Relay Output
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 10
No®Go To 12
Caution: Stop All Actuations.
10 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Note: Check connectors - It is critical that the connector is free from any
signs of corrosion or deformities - Clean/repair as necessary.
Using a test light connected to battery voltage, probe the Fuel Pump ground circuit
at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 11
No®Repair the open/high resistance in the fuel pump ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
11 If there are no possible causes remaining, view repair. All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
12 Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
With a 12 volt test light connected to ground, probe the Fuel Pump Relay Fused B+
circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 13
No®Check for an open Fuel Pump fuse, repair cause of open. If OK,
replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
256
STARTING
*ENGINE CRANKS DOES NOT START ÐContinued