ignition CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Remove the Transmission Oil Pan and Oil Filter per the Service Information.
Install a new Transmission Oil Filter per Service Information.
Reinstall Transmission Oil Pan, and refill with new Transmission Fluid per the
Service Information.
Note: The Transmission Cooler must be flushed before prodceeding.
Start the engine, check and adjust the Transmission Fluid Level per Service
Information.
Allow the engine to idle for 10 minutes, in Park.
Flush the Transmission Oil Cooler per the Service Information.
Turn the ignition off.
Drain and refill the Transmission Fluid.
Flush the Transmission Oil Cooler again.
Start the engine, check and adjust the Transmission Fluid Level per Service
Information.
With the DRBIIIt, perform a Battery Disconnect.
Note: This must be done to re enable EMCC during an A/C Clutch engage-
ment.
The vehicle may exhibit intermittent shudder during the first few hundred miles.
Note: The oil will gradually penetrate the TCC friction material and the
shudder should disappear.
Erase the DTC and return the vehicle to the customer.
Did the Code reset or does the vehicle still shudder after a few thousand miles?All
Ye s®Replace the Torque Convertor per the Service Information. Note:
After replacing the Torque Convertor, use the DRBIII to perform
the TCC Break In procedure. This will prevent possible shudder
conditions.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Test Complete.
141
TRANSMISSION
P1798-WORN OUT/BURNT TRANSAXLE FLUID ÐContinued

TEST ACTION APPLICABILITY
2 With the DRBIIIt, Check the STARTS SINCE SET counter.
NOTE: This counter only applies to the last DTC set.
Is the STARTS SINCE SET counter 2 or less?All
Ye s®Go To 3
No®Go To 12
3 Turn the ignition off to the lock position.
CAUTION: Remove the Starter Relay from the IPM. This will prevent the
vehicle from being started in gear.
Install Transmission Simulator, Miller tool #8333 and the FWD Adapter Cable kit,
Miller tool #8333-1.
Ignition on, engine not running.
With the DRBIIIt, monitor the Trans Temp Volts.
On the Transmission Simulator place the Thermistor Voltage Selector Switch to all
three positions. Compare the DRBIIItreading with the numbers on the Transmis-
sion Simulator.
Pick one that best matches your readings.All
DRBIIItreadings always high.
Go To 4
DRBIIItreadings = simulator +/- 0.25 V
Go To 9
DRBIIItreadings always low
Go To 10
DRBIIItreadings erratic.
Go To 12
4 Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Disconnect the TRS harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Speed Sensor Ground circuit from the TCM harness
connector to the TRS harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Speed Sensor Ground circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 5
5 Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Disconnect the TRS harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Transmission Temperature Sensor Signal circuit from
the TCM harness connector to the TRS harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Transmission Temperature Sensor Signal circuit for
an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 6
143
TRANSMISSION
P1799-CALCULATED OIL TEMP IN USE ÐContinued

TEST ACTION APPLICABILITY
6 Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Disconnect the TRS harness connector.
Remove the Transmission Control Relay from the IPM.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire between the Fused B+ circuit and the Transmission Control
Relay Output circuit in the Transmission Control Relay connector in the IPM.
Ignition on, engine not running.
Measure the voltage of the Speed Sensor Ground circuit in the TCM harness
connector.
Is the voltage above 0.5 volt?All
Ye s®Repair Speed Sensor Ground circuit for a short to voltage.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 7
7 Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Remove the Transmission Control Relay from the IPM.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wire between the Fused B+ circuit and the Transmission Control
Relay Output circuit in the Transmission Control Relay connector in the IPM.
Ignition on, engine not running.
Measure the voltage of the Transmission Temperature Sensor Signal circuit in the
TCM harness connector.
Is the voltage above 8.0 volts?All
Ye s®Repair Transmission Temperature Sensor Signal circuit for a
short to voltage.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 8
8 If there are no possible causes remaining, view repair. All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
9 If there are no possible causes remaining, view repair. All
Repair
If the temperature readings are correct with the simulator in-
stalled, the problem must be internal.Replace TRS assembly as
required.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
144
TRANSMISSION
P1799-CALCULATED OIL TEMP IN USE ÐContinued

TEST ACTION APPLICABILITY
10 Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Disconnect the TRS harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the Transmission Temperature Sensor
Signal circuit.
Is the resistance below 5.0 ohms?All
Ye s®Repair Transmission Temperature Sensor Signal circuit shorted
to ground.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 11
11 If there are no possible causes remaining, view repair. All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
12 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?All
Ye s®Repair as necessary.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Test Complete.
145
TRANSMISSION
P1799-CALCULATED OIL TEMP IN USE ÐContinued

Symptom:
*BRAKE SHIFT INTERLOCK OUTPUT OPEN
POSSIBLE CAUSES
INTERMITTENT WIRING AND CONNECTORS
BRAKE SHIFT INTERLOCK CONTROL CIRCUIT OPEN
BRAKE SHIFT INTERLOCK FEED CIRCUIT OPEN
BRAKE SHIFT INTERLOCK SOLENOID
FRONT CONTROL MODULE
TEST ACTION APPLICABILITY
1 Ignition on, engine not running.
With the DRBIIIt, record and erase DTC's.
Turn the ignition off to the lock position.
Turn the ignition on.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay BRAKE SHIFT INTERLOCK OUTPUT OPEN?All
Ye s®Go To 2
No®Go To 8
2 Turn the ignition off to the lock position.
Disconnect the Brake Shift Interlock harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Using a 12-volt test light connected to B+, check the Brake Shift Interlock Control
circuit in the Brake Shift Interlock harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Go To 6
3 Turn the ignition off to the lock position.
Disconnect the Brake Shift Interlock harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Using a 12-volt test light connected to ground, check the Brake Shift Interlock Feed
circuit in the Brake Shift Interlock harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s®Go To 4
No®Go To 5
4 If there are no possible causes remaining, view repair. All
Repair
Replace the Brake Shift Interlock Solenoid in accordance with the
Service Information.
146
TRANSMISSION

TEST ACTION APPLICABILITY
5 Turn the ignition off to the lock position.
Disconnect the Front Control Module harness connector.
Disconnect the Brake Shift Interlock harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Brake Shift Interlock Feed Circuit from the Front
Control Module connector to the Brake Shift Interlock harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Brake Shift Interlock Feed Circuit for an open.
No®Go To 7
6 Turn the ignition off to the lock position.
Disconnect the Front Control Module harness connector.
Disconnect the Brake Shift Interlock harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Brake Shift Interlock Control Circuit from the Front
Control Module connector to the Brake Shift Interlock harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Brake Shift Interlock Control Circuit for an open.
No®Go To 7
7 If there are no possible causes remaining, view repair. All
Repair
Replace the Front Control Module in accordance with the Service
Information.
8 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?All
Ye s®Repair as necessary.
No®Test Complete.
147
TRANSMISSION
*BRAKE SHIFT INTERLOCK OUTPUT OPEN ÐContinued

Symptom:
*CHECKING PARK/NEUTRAL SWITCH OPERATION
POSSIBLE CAUSES
P/N POSITION SWITCH SENSE CIRCUIT OPEN
P/N POSITION SWITCH SENSE CIRCUIT SHORTED TO GROUND
TRANSMISSION RANGE SENSOR
PCM - P/N POSITION SWITCH
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read the Park/Neutral Position Switch input state.
While moving the gear selector through all gear positions, Park to 1 and back to Park,
watch the DRBIIItdisplay.
Did the DRBIIItdisplay show P/N and D/R in the correct gear positions?All
Ye s®Test Complete.
No®Go To 2
2 Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Transmission Range Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the P/N Position Switch Sense circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Repair the P/N Position Switch Sense circuit for an open.
3 Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Transmission Range Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the P/N Position Switch Sense circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 4
No®Repair the P/N Position Switch Sense circuit for a short to ground.
4 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
Ye s®Go To 5
No®Replace the Transmission Range Sensor.
148
TRANSMISSION

TEST ACTION APPLICABILITY
5 Turn the ignition off to the lock position.
Disconnect the Left Reverse Lamp harness connector per the service information.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the Reverse Lamp Ground circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Reverse Lamp Ground circuit for an open.
6 Turn the ignition off to the lock position.
Disconnect the Left Reverse Lamp harness connector per the service information.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance across the Reverse Lamp contacts.
Is the resistance above 5.0 ohms?All
Ye s®Replace the Reverse Lamp.
No®Go To 7
7 Turn the ignition off to the lock position.
Disconnect the Right Reverse Lamp harness connector per the service information.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the Reverse Lamp Ground circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair the Reverse Lamp Ground circuit for an open.
8 Turn the ignition off to the lock position.
Disconnect the Right Reverse Lamp harness connector per the service information.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance across the Reverse Lamp contacts.
Is the resistance above 5.0 ohms?All
Ye s®Replace the Reverse Lamp.
No®Go To 9
9 Turn the ignition off to the lock position.
Disconnect the TRS harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the TRS Ground circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 10
No®Repair the TRS Ground circuit for an open.
10 Turn the ignition off to the lock position.
Disconnect the IPM harness connector.
Disconnect the TRS harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance of the TRS Reverse Sense circuit between the IPM connector
and the TRS connector.
Is the resistance below 5.0 ohms?All
Ye s®Test Complete.
No®Repair the TRS Reverse Sense circuit for an open.
152
TRANSMISSION
*NO BACK UP LAMP OPERATION ÐContinued

POWERTRAIN VERIFICATION TEST VER - 2 APPLICABILITY
1. NOTE: If the PCM has been replaced and the correct VIN and mileage have not
been programmed, a DTC will be set in the ABS Module, Airbag Module and the
SKIM.
2. NOTE: If the vehicle is equipped with a Sentry Key Immobilizer System, Secret
Key data must be updated. Refer to the Service Information for the PCM, SKIM and
the Transponder (ignition key) for programming information.
3. Inspect the vehicle to ensure that all components related to the repair are connected
properly.
4. With the DRBIIIt, clear DTCs and Reset Memory all engine values.
5. Run the engine for one warm-up cycle to verify proper operation.
6. Road test the vehicle. Use all accessories that may be related to this repair.
7. With the DRBIIIt, confirm that no DTC's or Secondary Indicators are present and that all
components are functioning properly.
8. If this test is being performed after a No Trouble Code test, verify the symptom is no longer
present.
9. If the symptom is still present, or any other symptom or DTC is present refer to the
appropriate category and perform the corresponding symptom.
10. Refer to any Technical Service Bulletins that may apply.
11. If there are no DTCs present and all components are functional properly, the repair is
complete.
Are any DTCs present?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
158
VERIFICATION TESTS
Verification Tests ÐContinued

9.0 CONNECTOR PINOUTS
AUTOSTICK SWITCH - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 T55 20YL/VT AUTOSTICK/OVERDRIVE OFF MUX INPUT
2 Z65 20BK/YL GROUND
BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAYCAV CIRCUIT FUNCTION
1 L61 18WT/LG LEFT FRONT TURN SIGNAL DRIVER
2 L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER
3 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
4 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER
5 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 G25 20VT/TN (EXCEPT
LOWLINE)LIFTGATE SWITCH MUX
7 A114 20GY/RD FUSED B(+) (I.O.D.)
8- -
9 L1 18WT/LG BACK-UP LAMP DRIVER
10 P3 20TN/WT LEFT FRONT DOOR LOCK DRIVER
11 P2 20TN/GY RIGHT FRONT DOOR LOCK DRIVER
12 P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER
13 - -
14 - -
15 Z15 18BK/TN GROUND
16 G920 20VT/YL (MEMORY) MEMORY SELECT SWITCH RETURN
17 G153 20VT/YL (POWER
LIFTGATE)LIFTGATE MODULE WAKE UP SIGNAL
18 P32 20TN/VT LEFT SLIDING DOOR LOCK DRIVER
19 Z10 18BK/TN GROUND
20 P5 20TN/OR LEFT SLIDING DOOR UNLOCK DRIVER
21 - -
22 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE
23 - -
24 G200 20VT/BR (MEMORY) MEMORY SELECT SWITCH MUX
25 M22 20YL/OR COURTESY LAMPS DRIVER
26 P4 20TN/BR RIGHT FRONT DOOR UNLOCK DRIVER
27 P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER
28 P1 20TN/LG LEFT FRONT DOOR UNLOCK DRIVER
29 - -
30 - -
31 - -
32 W13 18BR/LG REAR WIPER MOTOR CONTROL
33 M24 20YL/WT COURTESY LAMPS DRIVER
34 - -
C
O
N
N
E
C
T
O
R
P
I
N
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T
S
163
CONNECTOR PINOUTS