Chrysler RG Voyager. Manual - part 529

TABLE OF CONTENTS - Continued

P0700-TRANSMISSION CONTROL SYSTEM/READ TRANSMISSION DTCS
ON THE DRBIII

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

P0850-PARK/NEUTRAL SWITCH PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .254
P1115-GENERAL TEMP SENSOR PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .255
P1593-SPEED CONTROL SWITCH STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
P1603-PCM INTERNAL DUAL-PORT RAM COMMUNICATION . . . . . . . . . . . . . . . . .262
P1604-PCM INTERNAL DUAL-PORT RAM READ/WRITE INTEGRITY FAILURE . . .262
P1607-PCM INTERNAL SHUTDOWN TIMER RATIONALITY . . . . . . . . . . . . . . . . . . .262
P1696-EEPROM MEMORY WRITE DENIED/INVALID . . . . . . . . . . . . . . . . . . . . . . . . .263
P1697-EMR (SRI) MILEAGE NOT STORED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
P2074-MANIFOLD PRESSURE/THROTTLE POSITION CORRELATION - HIGH
FLOW/VACUUM LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
P2096-DOWN STREAM FUEL SYSTEM 1/2 LEAN . . . . . . . . . . . . . . . . . . . . . . . . . . .271
P2097-DOWN STREAM FUEL SYSTEM 1/2 RICH . . . . . . . . . . . . . . . . . . . . . . . . . . .271
P2302-IGNITION COIL #1 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION . . .274
P2305-IGNITION COIL #2 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION . . .274
P2308-IGNITION COIL #3 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION . . .274
P2503-CHARGING SYSTEM VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
U0101-NO TRANSMISSION BUS MESSAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
U0140-NO BODY BUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
U0155-NO CLUSTER BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284
U0168-NO SKIM BUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
U110C-NO FUEL LEVEL BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
*CHECKING PCM POWER AND GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . .289
*CHECKING THE A/C RELAY OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290

SKREEM
ANTENNA FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
COP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
EEPROM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
RAM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
ROM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
SERIAL LINK INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
STACK OVERFLOW FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
BCM MESSAGE MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
PCM STATUS FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
SERIAL LINK EXTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
ROLLING CODE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
VIN MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
TRANSPONDER COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
TRANSPONDER ID MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
TRANSPONDER RESPONSE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
UNPROGRAMMED KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302

STARTING
*CHECKING FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
*CHECKING FUEL PRESSURE LEAK DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
*CHECKING HARD START (FUEL DELIVERY SYSTEM) . . . . . . . . . . . . . . . . . . . . . .307
*ENGINE CRANKS DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
*NO CRANK CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314
*NO RESPONSE FROM PCM WITH A NO START CONDITION . . . . . . . . . . . . . . . .317
*START AND STALL CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318

TABLE OF CONTENTS - Continued

VERIFICATION TESTS
VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321

8.0

COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327

8.1

CONTROL MODULES AND FUSE & RELAY CENTER . . . . . . . . . . . . . . . . . . .327

8.2

CONTROLS AND SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327

8.3

DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329

8.4

SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330

8.5

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332

8.6

SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333

9.0

CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335

A/C PRESSURE SENSOR - GRAY 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335
AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .335
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .335
CAMSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . .335
CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . .336
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
EGR SOLENOID (3.8L LATE BUILD/3.3L) - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . .336
ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . .336
ENGINE OIL PRESSURE SWITCH (GAS) - LT. GREEN 2 WAY . . . . . . . . . . . . . . . . .337
EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .337
FUEL INJECTOR NO. 1 (2.4L/3.3L/3.8L) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .337
FUEL INJECTOR NO. 2 (2.4L/3.3L/3.8L) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .337
FUEL INJECTOR NO. 3 (2.4L/3.3L/3.8L) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .338
FUEL INJECTOR NO. 4 (2.4L/3.3L/3.8L) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .338
FUEL INJECTOR NO. 5 (3.3L/3.8L) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . .338
FUEL INJECTOR NO. 6 (3.3L/3.8L) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . .338
FUEL PUMP MODULE - LT. GRAY 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
GENERATOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
IDLE AIR CONTROL MOTOR (GAS) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . .339
IGNITION COIL (2.4L) - BLACK 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
IGNITION COIL (3.3L/3.8L) - DK. GRAY 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
INLET AIR TEMPERATURE SENSOR - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . .340
AUTO SHUT DOWN RELAY (GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
FUEL PUMP RELAY (GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
STARTER MOTOR RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
KNOCK SENSOR (2.4L/3.8L) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
LEFT SPEED CONTROL SWITCH - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .343
MANIFOLD ABSOLUTE PRESSURE SENSOR (GAS) - GRAY 3 WAY . . . . . . . . . . .343
NATURAL VACUUM LEAK DETECTION ASSEMBLY (EXCEPT EXPORT) -
LT. GRAY 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
OXYGEN SENSOR 1/1 UPSTREAM (2.4L) - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .344
OXYGEN SENSOR 1/1 UPSTREAM (3.3L/3.8L) - 4 WAY . . . . . . . . . . . . . . . . . . . . . .344
OXYGEN SENSOR 1/2 DOWNSTREAM (GAS) - 4 WAY . . . . . . . . . . . . . . . . . . . . . .344
POWERTRAIN CONTROL MODULE C1 - BLACK/BLACK 38 WAY . . . . . . . . . . . . . .345
POWERTRAIN CONTROL MODULE C2 - BLACK/ORANGE 38 WAY . . . . . . . . . . . .346
POWERTRAIN CONTROL MODULE C3 - BLACK/NATURAL 38 WAY . . . . . . . . . . . .347
POWERTRAIN CONTROL MODULE C4 - BLACK/GREEN 38 WAY. . . . . . . . . . . . . .348
RADIATOR FAN NO. 1 (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
RADIATOR FAN NO. 2 (GAS) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349

TABLE OF CONTENTS - Continued

RADIATOR FAN RELAY (GAS) - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . .349
SENTRY KEY REMOTE ENTRY MODULE (SKREEM) - BLACK 6 WAY . . . . . . . . . .349
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .350
THROTTLE POSITION SENSOR (GAS) - GRAY 3 WAY . . . . . . . . . . . . . . . . . . . . . . .350
VEHICLE SPEED SENSOR (MTX) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .350

10.0

SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351

10.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

11.0

CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353

NOTE (NGC)

The RS is equipped with the Powertrain
Control Module and Transmission Control
Module combined in a single control module.
This

module

the

Next

Generation

Controller (NGC) for DaimlerChrysler and will
be referred to as the Powertrain Control
Module (PCM).
The PCM has four color coded connectors C1
through C4, (C1 - BLK, C2 - ORANGE, C3 -
WHITE, C4 - GREEN), with each connector
containing 38 pins.
Two tools are required to diagnose and repair
the PCM terminals and harness connectors:

1. Miller #3638 Terminal Removal Pick must

used

release

the

connector

terminals

harness

and

connector

damage will occur.

2. Miller #8815 Pinout Box must be used to

probe the PCM terminals or terminal
damage will occur.

1.0

INTRODUCTION

The procedures contained in this manual include

specifications, instructions, and graphics needed to
diagnose the PCM Powertrain System. The diag-
nostics in this manual are based on the failure
condition or symptom being present at time of
diagnosis.

Please follow the recommendations below when

choosing your diagnostic path.

1. First make sure the DRBIII

t is communicating

with the appropriate modules; ie., if the DRBIII

displays a No Response condition, you must
diagnose this first before proceeding.

2. Read DTC’s (diagnostic trouble codes) with the

DRBIII

3. If no DTC’s are present, identify the customer

complaint.

4. Once the DTC or customer complaint is identi-

fied, locate the matching test in the Table of
Contents and begin to diagnose the symptom.

All component location views are in Section 8.0.

All connector pinouts are in Section 9.0. All system
schematics are in Section 10.0.

An * placed before the symptom description indi-

cates a customer complaint.

When repairs are required, refer to the appropri-

ate service information for the proper removal and
repair procedure.

Diagnostic procedures change every year. New

diagnostic systems may be added; carryover sys-
tems may be enhanced. READ THIS DIAGNOSTIC
INFORMATION BEFORE TRYING TO DIAG-
NOSE A VEHICLE CODE. It is recommended that
you review the entire diagnostic information to
become familiar with all new and changed diagnos-
tic procedures.

If you have any comments or recommendations

after reviewing the diagnostic information, please
fill out the form at the back of the book and mail it
back to us.

1.1

SYSTEM COVERAGE

This diagnostic procedures manual covers the

2005 RS vehicle equipped with the 2.4L and the
3.3L/3.8L engines.

1.2

SIX-STEP TROUBLESHOOTING
PROCEDURE

Diagnosis of the powertrain control module

(PCM) is done in six basic steps:

•

verification of complaint

•

verification of any related symptoms

•

symptom analysis

•

problem isolation

•

repair of isolated problem

•

verification of proper operation

2.0

IDENTIFICATION OF
SYSTEM

The Powertrain Control Module (PCM) monitors

and controls:

•

Fuel System

•

Idle Air Control System

•

Ignition System

•

Charging System

•

Speed Control System

•

Cooling system

3.0

SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION

3.1

GENERAL DESCRIPTION

These Sequential Fuel Injection (SFI) engine sys-

tems have the latest in technical advances. The
OBDII/EOBD diagnostics incorporated with the
Powertrain Control Module (PCM) are intended to

GENERAL INFORMATION

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