Chrysler Voyager. Manual — part 28

TEST

ACTION

APPLICABILITY

7

Disconnect the vacuum hose from the EGR Valve. Inspect the vacuum hose for any
obstructions.
Connect a Vacuum Pump to the EGR Valve.
Start the engine.
Using the Vacuum Pump, apply vacuum to the EGR Valve.
Does the engine run rough or stall at idle?

All

Yes

→ Go To 8

No

→ Remove the EGR Valve and inspect the valve for an obstruction

that would keep the valve form opening. If OK, replace the EGR
Valve.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

8

Turn the igntion off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Using a 12-volt Test Light connected to ground, probe the (F202) Fused Ignition
Switch Output circuit in the EGR Solenoid harness connector.
Does the 12-volt test light illuminate?

All

Yes

→ Go To 9

No

→ Repair the (F202) Fused Ignition Switch Output circuit for an

open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

9

Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Measure the voltage of the (K35) EGR Solenoid Control circuit in the EGR Solenoid
connector.
Is the voltage above 1.0 volts?

All

Yes

→ Repair the (K35) EGR Solenoid Control circuit for a short to

voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

No

→ Go To 10

10

Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the (K35) EGR Solenoid Control circuit between the PCM
harness connector and the EGR Solenoid harness connector.
Is the resistance below 5.0 ohms?

All

Yes

→ Go To 11

No

→ Repair the (K35) EGR solenoid control circuit for an open.

Perform POWERTRAIN VERIFICATION TEST VER - 5.

111

DRIVEABILITY - SBEC

P0401 - EGR SYSTEM FAILURE —

Continued

TEST

ACTION

APPLICABILITY

11

Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Using a 12-volt test light connected to 12-volts, probe the (K35) EGR Solenoid
Control circuit in the EGR Solenoid harness connector.
Turn the ignition on.
With the DRBIII

t, actuate the EGR Solenoid.

Observe the test light.
Does the test light flash on and off.

All

Yes

→ Inspect the EGR Solenoid Back Pressure hose and tube for

obstructions or damage. If OK, replace the EGR Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

No

→ Go To 12

12

NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.

All

Repair

Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

112

DRIVEABILITY - SBEC

P0401 - EGR SYSTEM FAILURE —

Continued

Symptom:

P0403 - EGR SOLENOID CIRCUIT

When Monitored and Set Condition:

P0403 - EGR SOLENOID CIRCUIT

When Monitored:

Engine running. Battery voltage greater than 10.4 volts.

Set Condition:

The EGR solenoid control circuit is not in the expected state when

requested to operate by the PCM for 86.4 seconds.

POSSIBLE CAUSES

GOOD TRIP EQUAL TO ZERO

EGR SOLENOID

(F202) FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN

(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO VOLTAGE

(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND

(K35) EGR SOLENOID CONTROL CIRCUIT OPEN

PCM

TEST

ACTION

APPLICABILITY

1

Turn the ignition on.
With the DRBIII

t, read DTC’s.

Is the Good Trip displayed and equal to zero?

All

Yes

→ Go To 2

No

→ Refer to the INTERMITTENT CONDITION symptom in the

Driveability category.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

2

Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Turn all accessories off.
Using a 12-volt Test Light connected to the (F202) Fused Ignition Switch Output
circuit, probe the EGR Solenoid Control circuit.
With the DRBIII

t, actuate the EGR solenoid.

Does the 12-volt test light flash on and off?

All

Yes

→ Inspect the EGR Valve Back Pressure hose and tube for obstruc-

tions or damage. If OK, replace the EGR Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

No

→ Go To 3

113

DRIVEABILITY - SBEC

TEST

ACTION

APPLICABILITY

3

Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Using a 12-volt Test Light connected to ground, probe the (F202) Fused Ignition
Switch Output circuit in the EGR Solenoid harness connector.
Does the 12-volt test light illuminate?

All

Yes

→ Go To 4

No

→ Repair the open in the (F202) Fused Ignition Switch Output

circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

4

Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the (K35) EGR Solenoid Control circuit to ground.
Is the resistance below 5.0 ohms?

All

Yes

→ Repair the short to ground in the (K35) EGR Solenoid Control

circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

No

→ Go To 5

5

Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Measure the voltage on the (K35) EGR Solenoid Control circuit in the EGR Solenoid
connector.
Is the voltage above 1.0 volt?

All

Yes

→ Repair the short to voltage in the (K35) EGR Solenoid Control

circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

No

→ Go To 6

6

Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the EGR Solenoid harness connector.
Measure the resistance of the (K35) EGR Solenoid Control circuit between the PCM
harness connector and the EGR Solenoid harness connector.
Is the resistance below 5.0 ohms?

All

Yes

→ Go To 7

No

→ Repair the open in the (K35) EGR Solenoid Control circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 5.

7

NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.

All

Repair

Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.

114

DRIVEABILITY - SBEC

P0403 - EGR SOLENOID CIRCUIT —

Continued