Chrysler RG Voyager. Manual — part 417

POSSIBLE CAUSES

CHECKING THE FUEL DELIVERY SYSTEM

FUEL INJECTOR(S)

FUEL PRESSURE SOLENOID

FUEL PRESSURE SOLENOID

FUEL PUMP

FUEL PUMP

FUEL SYSTEM CONTAMINATION

FUEL SYSTEM LEAK

INTERMITTENT CONDITION

TEST

ACTION

APPLICABILITY

1

WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL
INJECTORS. THIS MAY BE AS HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL
LEAKS.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN
SERVICING FUEL SYSTEM.
Turn the ignition on.
With the DRBIII

t, read the ECM DTCs.

Are there any other DTCs present?

All

Yes

→ Refer to symptom list for problems related to the DTC other than

this DTC.
Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 2

2

Turn the ignition on.
With the DRBIII

t, erase the ECM DTCs.

Attempt to start the engine.
Does the engine start and idle?

All

Yes

→ Go To 3

No

→ Go To 13

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TEST

ACTION

APPLICABILITY

3

Turn the ignition off.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL
INJECTORS. THIS MAY BE AS HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL
LEAKS.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN
SERVICING FUEL SYSTEM.
Inspect the entire fuel system for leakage.
Is there any evidence of leakage?

All

Yes

→ Repair as necessary in accordance with the Service Information.

Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 4

4

NOTE: Mixing any other fuels such as gasoline or kerosine can cause this
DTC to set.
Turn the ignition off.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL
INJECTORS. THIS MAY BE AS HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL
LEAKS.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN
SERVICING FUEL SYSTEM.
Inspect the fuel system for contamination.
Is the fuel contaminated?

All

Yes

→ Repair as necessary in accordance with the Service Information.

Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 5

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TEST

ACTION

APPLICABILITY

5

NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB III

t at the same time the DTC is

displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
NOTE: Refer to the Service Information and perform the Air Bleed Proce-
dure before continuing diagnosis.
Turn the ignition on.
With the DRBIII

t, erase the ECM DTCs.

Start and idle the engine while monitoring for ECM DTC’s.
If the DTC does not reset at idle condition, test drive the vehicle under various load
and speed conditions to attempt to duplicate the fault.
NOTE: Driving the vehicle up and down steep hills or rapid cornering with
a low fuel level can cause this DTC to set. Verify with customer if Low Fuel
Light was illuminated when fault occurred.
With the DRBIII

t, read the ECM DTCs.

Does the DRBIII

t display this DTC?

All

Yes

→ Go To 6

No

→ Go To 12

6

Start the engine.
With the DRBIII

t in Sensors, compare the Fuel Pressure Setpoint with the Actual

Fuel Pressure readings.
NOTE: If there is air in the fuel system, the Actual Fuel Pressure will
oscillate above and below the Fuel Pressure Setpoint.
Does Actual Fuel Pressure oscillate above and below the Fuel Pressure Setpoint?

All

Yes

→ Refer to the Service Information to purge air from the fuel system.

Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 7

7

Start the engine.
With the DRBIII

t in Sensors, compare the Fuel Pressure Setpoint with the Actual

Fuel Pressure readings.
NOTE: A sticking Fuel Pressure Solenoid is indicated by Actual Fuel
Pressure gradually dropping below the Fuel Pressure Setpoint then sud-
denly increasing (spiking) above the Fuel Pressure Setpoint.
Does Actual Fuel Pressure gradually decrease then suddenly increase (spike) above
the Fuel Pressure

All

Yes

→ Replace the Fuel Pressure Solenoid in accordance with the

Service Information.
Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 8

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TEST

ACTION

APPLICABILITY

8

Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel
Delivery System table.
NOTE: The following is a list of problems that can cause fuel pressure to
deviate from specification: restricted fuel filter or fuel lines, failed fuel
pressure solenoid, air in fuel system, failed fuel sending unit, contaminated
fuel, faulty injector.
Were there any problems with the Fuel Delivery System?

All

Yes

→ Repair as necessary in accordance with the Service Information.

Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 9

9

Refer to each of the following symptoms in the Driveability category.
CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS
CHECKING THE FUEL PRESSURE SENSOR CIRCUITS
Were any problems found?

All

Yes

→ Repair as necessary.

Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 10

10

NOTE: An injector that sticks open can cause this DTC. A sticking injector
will cause the engine to missfire and emit excessive black smoke from the
exhaust system.
Refer to the Service Information and perform the Fuel Injector Leak Quantity during
engine cranking test.
Were any problems found?

All

Yes

→ Using the Service Information, remove and inspect the Fuel

Injectors for signs of damage or debris that may cause the injector
to stick. Sticking injectors may cause the combustion chamber to
become black and oil soaked. Replace Injector(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 11

11

Turn the ignition off.
Replace the Fuel Pressure Solenoid in accordance with the Service Information.
Turn the ignition on.
With the DRBIII

t, erase the ECM DTCs.

Attempt to start and test drive the vehicle.
With the DRBIII

t, read the ECM DTCs.

Did this DTC set again?

All

Yes

→ Replace the Fuel Pump in accordance with the Service Informa-

tion.
Perform ROAD TEST VERIFICATION - VER-2.

No

→ Test Complete.

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Continued