Chrysler Voyager. Manual — part 122

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 5/16 fuel line adapter tool #6539 between the disconnected fuel line
and the fuel pump module.
Attach a fuel pressure test gauge to the T fitting on the 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 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

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.

7

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

Yes

→ Repair as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

No

→ Test Complete.

487

STARTING

*ENGINE CRANKS DOES NOT START —

Continued

TEST

ACTION

APPLICABILITY

8

Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIII

t, 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

Yes

→ Go To 9

No

→ Go To 11

Caution: Stop All Actuations.

9

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 12 - volt 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

Yes

→ Go To 10

No

→ Repair the open/high resistance in the fuel pump ground circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

10

If there are no possible causes remaining, view repair.

All

Repair

Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER - 1.

11

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

Yes

→ Go To 12

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.

12

Turn the ignition off.
Disconnect the IPM harness connector.
Disconnect the Fuel Pump Module harness connector.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM
harness connector and the Fuel Pump Module connector.
Is the resistance below 5.0 ohms?

All

Yes

→ Go To 13

No

→ Repair the open fuel pump relay output circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

488

STARTING

*ENGINE CRANKS DOES NOT START —

Continued

TEST

ACTION

APPLICABILITY

13

NOTE: Ensure all IPM harness connector are connected.
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Remove the Fuel Pump Relay from the IPM.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM and
the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?

All

Yes

→ Replace the Fuel Pump Relay.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

No

→ Replace the IPM Fused & Relay Center.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

489

STARTING

*ENGINE CRANKS DOES NOT START —

Continued

Symptom:

*NO CRANK CONDITION

POSSIBLE CAUSES

REPAIR MECHANICAL CONDITION

TRANSMISSION RANGE SENSOR

BATTERY CIRCUIT RESISTANCE TOO HIGH

IGNITION SWITCH OUTPUT CIRCUIT OPEN

STARTER RELAY CONTROL CIRCUIT OPEN

STARTER RELAY OUTPUT CIRCUIT OPEN

FUSED B(+) CIRCUIT OPEN

FUSED IGNITION SWITCH OUTPUT (START) CIRCUIT OPEN

STARTER

STARTER MOTOR RELAY

STARTER RELAY

TEST

ACTION

APPLICABILITY

1

NOTE: Check all PCM powers and grounds before continuing.
NOTE: Ensure that SKIS is operating properly. Check the SKIM for DTC. If
a SKIM DTC(s) is present diagnose them first before continuing.
WARNING: MAKE SURE THE BATTERY IS DISCONNECTED, THEN WAIT
TWO MINUTES BEFORE PROCEEDING.
Turn the engine over by hand to ensure the engine is not seized.
Is the engine able to turn over?

All

Yes

→ Go To 2

No

→ Repair the mechanical condition preventing the starter motor

from cranking.
Perform POWERTRAIN VERIFICATION TEST VER - 1.

2

Turn the ignition off.
Disconnect the PCM harness connectors.
Move the Gear selector through all gear positions, from Park to 1st and back.
While moving the gear selector through each gear, measure the resistance between
ground and the P/N Position Switch Sense circuit.
Did the resistance change from above 10.0 ohms to below 10.0 ohms?

All

Yes

→ Go To 3

No

→ Replace the Transmission Range Sensor.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

3

Turn the ignition off.
Check the Battery Cables for high resistance using the service information proce-
dure.
Did either Battery Cable have a voltage drop greater than 0.2 volt?

All

Yes

→ Repair the Battery circuit for high resistance.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

No

→ Go To 4

490

STARTING