Chrysler Voyager. Manual — part 116

TEST

ACTION

APPLICABILITY

2

Turn the ignition off.
Remove the ignition wire.
Measure the resistance of the ignition wire.
Is the resistance below 10K ohms?

All

Yes

→ Go To 3

No

→ Replace the Ignition Wire.

Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.

3

Turn the ignition off.
Disconnect the Ignition Coil harness connector.
Remove the ignition coil.
NOTE: Before continuing inspect the Ignition Coil for damage or carbon
tracking coil or the spark plug insulator boot. If a problem is found, replace
the ignition coil.
Install a spark tester to the Ignition Coil.
Reconnect the Ignition Coil harness connector to the Ignition Coil.
While cranking the engine observe the spark coming from the spark tester.
NOTE: The Ignition Coil should generate a crisp blue spark that is able to
jumper the gap of the spark tester.
Does the Ignition Coil generate a good spark.

All

Yes

→ Replace the Spark Plug.

Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.

No

→ Replace the Ignition Coil.

Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.

4

Turn the ignition off.
Remove the Spark Plug.
Inspect the Spark Plug for the following conditions.
- Cracks
- Carbon Tracking
- Foreign Material
- Gap size out of specifications
- Loose or broke electrode
NOTE: Lightly tap the bottom of the spark plug on a solid surface. The
electrode in the spark plug should not move.
Were any of the above condition present?

All

Yes

→ Replace the Spark Plug.

Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.

No

→ Refer to the INTERMITTENT CONDITION symptom in the

Driveability category.
Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.

463

DRIVEABILITY - NGC

P2302-IGNITION COIL #1 SECONDARY CIRCUIT-INSUFFICIENT ION-
IZATION —

Continued

Symptom:

P2503-CHARGING SYSTEM VOLTAGE LOW

When Monitored and Set Condition:

P2503-CHARGING SYSTEM VOLTAGE LOW

When Monitored:

The engine running. The engine speed greater than 1157 RPM.

Set Condition:

The battery sensed voltage is 1 volt below the charging goal for 13.47

seconds. The PCM senses the battery voltage turns off the field driver and senses the
battery voltage again. If the voltages are the same, the code is set.

POSSIBLE CAUSES

CHARGING VOLTAGE BELOW 15.1 VOLTS

(A11) B+ CIRCUIT HIGH RESISTANCE

GENERATOR GROUND HIGH RESISTANCE

GENERATOR OPERATION

(Z1) GEN FIELD GROUND CIRCUIT OPEN

(K20) GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE

(K20) GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND

(K20) GEN FIELD CONTROL CIRCUIT OPEN

PCM

TEST

ACTION

APPLICABILITY

1

NOTE: Inspect the vehicle for aftermarket accessories that may exceed the
Generator System output.
Turn the ignition off.
NOTE: The battery must be fully charged.
NOTE: The Generator belt tension and condition must be checked before
continuing.
Start the engine.
Allow the idle to stabilize.
With the DRBIII

t, read the Target Charging Voltage.

Is the Target Charging Voltage above 15.1 volts?

All

Yes

→ Refer to the INTERMITTENT CONDITION symptom in the

Driveability category.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

No

→ Go To 2

464

DRIVEABILITY - NGC

TEST

ACTION

APPLICABILITY

2

WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Ignition on, engine not running.
NOTE: Ensure all wires are clear of the engine’s moving parts.
Start the engine.
Measure the voltage between the (A11) Generator B+ Terminal and the Battery+
Post.
Is the voltage above 0.4 of a volt?

All

Yes

→ Repair the (A11) B+ circuit for high resistance between the

Generator and Battery.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

No

→ Go To 3

3

WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Warm the engine to operating temperature.
NOTE: Ensure all wires are clear of the engine’s moving parts.
Measure the voltage between the Generator case and Battery ground post.
Is the voltage above 0.1 of a volt?

All

Yes

→ Repair Generator Ground for high resistance, Generator Case to

Battery ground side.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

No

→ Go To 4

4

Turn the ignition off.
Disconnect the Generator Field harness connector.
Using a 12-volt test light, jumper it across the Generator Field harness connector.
Ignition on, engine not running.
With the DRBIII

t, actuate the Gen Field Control circuit.

Does the test light illuminate brightly and flash on and off?

All

Yes

→ Replace the Generator.

Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

No

→ Go To 5

5

Turn the ignition off.
Disconnect the Generator Field harness connector.
Using a 12-volt test connected to battery voltage, probe the (Z1) Gen Field Ground
circuit in the Generator Field harness connector.
Does the test light illuminate brightly?

All

Yes

→ Go To 6

No

→ Repair the open in the (Z1) Gen Field Ground circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

465

DRIVEABILITY - NGC

P2503-CHARGING SYSTEM VOLTAGE LOW —

Continued

TEST

ACTION

APPLICABILITY

6

Turn the ignition off.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
Measure the voltage on the (K20) Gen Field Control circuit at the Generator Field
harness connector.
Is the voltage above 1.0 volt?

All

Yes

→ Repair the short to voltage in the (K20) Gen Field Control circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

No

→ Go To 7

7

Turn the ignition on.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
Measure the resistance between ground and the (K20) Gen Field Control circuit in
the Generator Field harness connector.
Is the resistance below 100 ohms?

All

Yes

→ Repair the (K20) Gen Field Control circuit for a short to ground.

Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

No

→ Go To 8

8

Turn the ignition off.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K20) Gen Field Control circuit from the Generator
Field harness connector to the appropriate terminal of the special tool #8815.
Is the resistance below 5.0 ohms?

All

Yes

→ Go To 9

No

→ Repair the open in the (K20) Generator Field Control circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.

9

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 - 3 - NGC.

466

DRIVEABILITY - NGC

P2503-CHARGING SYSTEM VOLTAGE LOW —

Continued