Chrysler Voyager. Manual — part 124

TEST

ACTION

APPLICABILITY

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.
Install a fuel pressure gauge to the fuel rail test port.
Turn the ignition on.
With the DRBIII

t, 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

4

Within Specification

Go To

6

Above Specification

Replace the fuel filter/fuel pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER - 1.

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.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16 fuel line adapter tool #6539 between the disconnected fuel line
and the fuel pump module.
Attach a fuel pressure test gauge to the

9T9 fitting on tool #6539.

Turn the ignition on.
With the DRBIII

t, 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

Yes

→ Repair/replace fuel supply line as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

No

→ Go To 5

Caution: Stop All Actuations.

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.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?

All

Yes

→ Replace the Fuel Pump Inlet Strainer.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

No

→ Replace the Fuel Pump Module.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

495

STARTING

*START AND STALL CONDITION —

Continued

TEST

ACTION

APPLICABILITY

6

Turn the ignition on.
With the DRBIII

t, read TPS VOLTS.

While monitoring the DRBIII

t, slowly open and close the Throttle.

Is the voltage change smooth?

All

Yes

→ Go To 7

No

→ Replace the Throttle Position Sensor.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

7

Turn the ignition on.
With the DRBIII

t, read Throttle Position voltage. Throttle must be against stop.

Is the voltage 0.92 or less with the Throttle closed?

All

Yes

→ Go To 8

No

→ Check for a binding throttle condition. If OK, replace the Throttle

Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1.

8

Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soaked).
NOTE: If the vehicle was allow to sit over night with no engine start, coolant
temperature should be near ambient temperatures.
Turn the ignition on.
With the DRBIII

t, read the Engine Coolant Temperature value.

Note: If engine coolant temperature is above 82° C (180° F), allow the engine
to cool until 65° C (150° F) is reached.
Start the engine.
During engine warm-up, monitor the Engine Coolant Temperature value. The
temperature value change should be a smooth transition from start up to normal
operating temp 82° C (180° F). The value should reach at least 82° C (180° F).
Did the Engine Temperature value increase smoothly and did it reach at least 82° C
(180° F)?

All

Yes

→ Go To 9

No

→ Replace the Engine Coolant Temperature Sensor.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

9

The following additional items should be checked as a possible cause for a start and
stall condition.
Refer to any Technical Service Bulletins (TSB’s) that may apply to the symptom.
Fuel must be free of contamination.
The exhaust system must be free of any restrictions.
The engine compression must be within specifications.
The engine valve timing must be within specifications.
The engine must be free from vacuum leaks.
The throttle body must be free of carbon buildup and dirt.
Do any of the above conditions exist?

All

Yes

→ Repair as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

No

→ Test Complete.

496

STARTING

*START AND STALL CONDITION —

Continued

Verification Tests

41TE TRANSMISSION VERIFICATION TEST - VER 1.

APPLICABILITY

1. Connect the DRBIII

t to the Data Link Connector (DLC).

2. Reconnect any disconnected components.
3. With the DRBIII

t, erase all Transmission DTC’s, also erase the PCM DTC’s.

4. With the DRBIII

t, display transmission temperature. Start and run the engine until the

transmission temperature is HOT (above 110 deg. F).
5. Check the transmission fluid and adjust if necessary. Refer to the Service information for the
Fluid Fill procedure.
6. NOTE: If the Transmission Control Module or torque converter has been replaced
or if the transmission has been repaired or replaced it is necessary to perform the
DRBIII

t Quick Learn Procedure and reset the (Pinion Factor(

7. Road test the vehicle. With the DRBIII

t, monitor the engine RPM. Make 15 to 20 1-2, 2-3,

3-4 upshifts. Perform these shifts from a standing start to 45 MPH with a constant throttle
opening of 20 to 25 degrees.
8. Below 25 MPH, make 5 to 8 wide open throttle kickdowns to 1st gear. Allow at least 5 seconds
each in 2nd and 3rd gear between each kickdown.
9. For a specific DTC, drive the vehicle to the Symptom’s When Monitored/When Set conditions
to verify the DTC repair.
10. Check for Diagnostic Trouble Codes (DTC’s) during the road test. If a DTC sets during the
road test , return to the Symptom list and follow the path.
11. NOTE: Erase P0700 DTC in the PCM to turn the MIL light off after making
transmission repairs. This will turn the MIL off.
Were any Trouble Codes set during the road test?

All

Yes

→ Refer to the Symptom List for appropriate diagnostic tests.

No

→ Repair is complete.

497

VERIFICATION TESTS

BODY VERIFICATION TEST - VER 1

APPLICABILITY

1. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
2. NOTE: If the SKIM, PCM/ECM or FCM was replaced, refer to the service informa-
tion for proper programming procedures.
3. If the Body Control Module (BCM) was replaced, turn the ignition on for 15 seconds (to allow
the new BCM to learn VIN) or engine may not start (if VTSS equipped). If the vehicle is
equipped with VTSS, use the DRBIII

t and enable VTSS.

4. Program all RKE transmitters and other options as necessary.
5. If any HVAC door actuator circuits were repaired, with the DRBIII

t in HVAC, System Tests,

select Actuator Circuit Test. (Manual Temp Control only).
6. If any actuators were replaced in the HVAC System, with the DRBIII

t in HVAC, select

System Tests then select HVAC Door Recalibration (Manual Temp Control only).
7. If any actuators were replaced in the ATC System, with the DRBIII

t in Automatic Temp

Control, select Miscellaneous then select Reset ATC Head.
8. For Three-Zone HVAC Systems, if HVAC Control/Rear Blower Rear Control was replaced/
Rear Blend Pot Circuit Open/Short DTC was set/any rear blend pot circuit was repaired,
proceed to Number 9 & 10.
9. With DRBIII

t in HVAC, select System Tests then select HVAC Door Recalibration. Door

Recalibration must pass before proceeding to next step.
10. With DRBIII

t in HVAC, select System Tests then select Reset Rear Blend Switch Span.

Rotate Rear Blend/Mode control on Rear Blower Rear Control to full cold. Wait five seconds,
then rotate control to full hot.
11. If any repairs were made to the power sliding door or power liftgate, use the DRBIII

t and

perform the open and close system tests. Observe the manuals on the DRBIII

t screen.

12. Ensure that all accessories are turned off and the battery is fully charged.
13. With the DRBIII

t, record and erase all DTCs from ALL modules. Start and run the engine

for 2 minutes. Operate all functions of the system that caused the original concern.
14. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII

t, read

DTCs from ALL modules.
Are any DTC’s present or is the original condition still present?

All

Yes

→ Repair is not complete, refer to the appropriate symptom.

No

→ Repair is complete.

POWERTRAIN VERIFICATION TEST VER - 1 - SBEC

APPLICABILITY

1. NOTE: If the PCM has been replaced and the correct VIN and mileage have not
been programmed, a DTC will be set in the ABS Module, Airbag Module and the
SKIM.
2. NOTE: If the vehicle is equipped with a Sentry Key Immobilizer System, Secret Key
data must be updated. Refer to the Service Information for the PCM, SKIM and the
Transponder (ignition key) for programming information.
3. Inspect the vehicle to ensure that all components related to the repair are connected properly.
4. Inspect the engine oil for fuel contamination. Replace the oil and filter as necessary.
5. Attempt to start the engine.
6. If the No Start condition is still present, refer to the symptom list and perform the diagnostic
testing as necessary. refer to any Technical Service Bulletins that may apply.
7. Run the engine for one warm-up cycle to verify operation.
8. With the DRBIII

t, confirm that no DTCs or Secondary Indicators are present and that all

components are functioning properly.
9. If a DTC is present, refer to the appropriate category and select the corresponding symptom.
Are any DTCs present?

All

Yes

→ Repair is not complete, refer to appropriate symptom.

No

→ Repair is complete.

498

VERIFICATION TESTS

Verification Tests —

Continued