Chrysler G voyager (Fix)

The Murky Voyager
A garage had contacted me to look into a Chrysler Voyager 2006, 3.3 L petrol Automatic; with poor acceleration and loosing power under load. The garage briefing was as follows:
1) No warning light and no fault logged by the ECU.
2) the Garage took the following action (progressively), but with no fix:
* the EGR was replaced.
* New fuel pump was fitted.
* The MAP sensor was replaced twice.
3) Suspecting the timing chain; the garage found that it was loose and was corrected with detailed check on timing marks, yet no fix.
4) At certain stage they did notice an intermittent loss of brake servo action.

My action was as follows:
I) Selected Live data was showing correct MAP signal in all modes of; Key on Engine off, Running at idle and also during wide open throttle in a test drive. But the following other live data did show something was not correct going on:
Crank Sync at Start Out of Sync
Cam Sync at Start Out of Sync
Cam Sync State In Sync
Cam Crank last lost Tolerance
Cam/Crank Difference 6534.50

2) Next I have connected my Vacuum/Pressure gauge to a good point in the inlet manifold and found the pointer stops at the 6 Clock position; on the Red LATEING TIMING. On this my friends in the garage insisted that the timing chain and even both cams (V-type engine) were 100% correct.
This was directing us towards; A correct Valve timing/incorrect and retarded ignition timing and I did requested lifting the car to Scope the Crankshaft sensor but this was not possible due to the Ramp was occupied; (No Wiring diagram was available, and the signal couldn’t be taken from the ECU). Then they recalled their memory of the possibility of a cracked or damaged Flywheel/signal ring gear; when earlier in the attempt to fix the car, a Chrysler Tech advised them of the possibility of a common fault of a cracked Flywheel.
My friends thanked me for doing a good job; i.e. leave us alone! Which was not a bad idea, as I discovered later that they did fix the car in the following unusual way:
A second hand flywheel was ordered to be discovered that it was an incorrect part when the transmission was removed, so this was not fitted and a new genuine one was purchased. This raised the doubt about wasting money on an expensive part that look exactly like the one behind the crankshaft. Just before agreeing that no option left but to fit this, the old flywheel accidentally dropped and the centre piece split and went off the main flywheel body; as the loaded photo is showing. The car was fixed with the new flywheel; Sure I have a share in this achievement, but missing the chance to scope the crank sensor, while my Scope was ready in my car boot!!
Bashar Alqasim

I would like to add the following to my previous message Re that Voyager:
When I got the story complete I have revisited the garage and left with two different opinions;
* Mine; That The cracked old flywheel was causing an offset in the circular position of the ring gear
shifting the crankshaft sensor signal.
* The garage owner opinion; that the crack was causing the flywheel and the ring gear to wobble and have a lateral movement affecting the signal. Sure Missing the Scope was a gap in this Job.

Interesting problem! I wonder if there is a tsb for that one?

Sent from my Moto G Play using Tapatalk

Cool case study, thanks for sharing

Wasn't there a Scanner Danner video with a similarly broken Jeep flywheel? I've been looking for it, but cannot seem to find it...