relay CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
6 Turn the ignition on.
With the DRB, actuate the Low Speed Rad Fan and observe the Radiator Fans.
NOTE: Both Radiator Fans should operate at low speed.
Did both Radiator Fans operate as they should?All
Ye s®Go To 7
Fans do not operate on Low
Go To 15
Fan 1 on High/Fan 2 not on
Go To 23
Fan 1 not on/Fan 2 on High
Go To 26
7 Turn the ignition on.
With the DRB, actuate the High and Low Speed Rad Fans at the same time and
observe the Radiator Fans.
NOTE: Both Radiator Fans should operate at high speed.
Did both Radiator Fans operate as they should?All
Ye s®The test is complete. Ensure the ECM will turn the fans on when
the engine is hot.
Perform ROAD TEST VERIFICATION - VER-2.
Fan 1 on High/Fan 2 not on
Go To 8
Fan 1 not on/Fan 2 on High
Go To 11
8 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 2 harness connector.
Using a 12-volt test light connected to ground, check the Fused B+ circuit.
Did the test light illuminate brightly?All
Ye s®Go To 9
No®Repair the Radiator Fan Relay No. 2 Fused B+ circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
9 Turn the ignition off.
Install a substitute relay in place of Radiator Fan Relay No. 2.
Turn the ignition on.
With the DRB, actuate the High Speed Fan Relay.
Does Radiator Fan No. 2 cycle on and off?All
Ye s®Replace Radiator Fan Relay No. 2.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 10
188
DRIVEABILITY - DIESEL
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION ÐContinued

TEST ACTION APPLICABILITY
10 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 2 harness connector.
Disconnect the Radiator Fan No. 2 harness connector.
Measure the resistance of the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit from Radiator Fan Relay No. 2.
Is the resistance below 5.0 ohms?All
Ye s®Test Complete.
No®Repair the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit from Radiator Fan Relay No. 2 for an open.
Perform ROAD TEST VERIFICATION - VER-2.
11 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Using a 12-volt test light connected to ground, check the Fused B+ circuit.
Did the test light illuminate brightly?All
Ye s®Go To 12
No®Repair the Radiator Fan Relay No. 3 Fused B+ circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
12 Turn the ignition off.
Install a substitute relay in place of Radiator Fan Relay No. 3.
Turn the ignition on.
With the DRB, actuate the High Speed Fan Relay and then actuate the Low Speed
Fan Relay.
Does Radiator Fan No. 2 cycle on and off and then both fans cycle on and off when
requested?All
Ye s®Replace Radiator Fan Relay No. 3.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 13
13 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the Radiator Fan No. 2 harness connector.
Using a 12-volt test light connected to 12-volts, check the Radiator Fan Relay No. 3
Ground circuit at the Radiator Fan Relay No. 3 harness connector.
Did the test light illuminate brightly?All
Ye s®Go To 14
No®Repair the Radiator Fan Relay No. 3 Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
14 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the High Speed Radiator Fan Dual Relay Control circuit.
Is the resistance below 5.0 ohms?All
Ye s®Test Complete.
No®Repair the High Speed Radiator Fan Dual Relay Control circuit
for an open.
Perform ROAD TEST VERIFICATION - VER-2.
189
DRIVEABILITY - DIESEL
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION ÐContinued

TEST ACTION APPLICABILITY
15 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 1 harness connector.
Using a 12-volt test light connected to ground, check the Fused B+ circuit.
Did the test light illuminate brightly?All
Ye s®Go To 16
No®Repair the Radiator Fan Relay No. 1 Fused B+ circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
16 Turn the ignition off.
Install a substitute relay in place of Radiator Fan Relay No. 1.
Turn the ignition on.
With the DRB, actuate the Low Speed Fan Relay.
Do both Radiator Fans cycle on and off?All
Ye s®Replace Radiator Fan Relay No. 1.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 17
17 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 1 harness connector.
Disconnect the Radiator Fan No. 1 harness connector.
Using a 12-volt test light connected to 12-volts, check the Radiator Fan Relay No. 1
Output circuit in the Radiator Fan Relay No. 1 harness connector.
Did the test light illuminate?All
Ye s®Repair the Radiator Fan Relay No. 1 Output circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 18
18 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the Radiator Fan No. 2 harness connector.
Using a 12-volt test light connected to 12-volts, check the Radiator Fan Relay No. 3
Ground circuit at the Radiator Fan Relay No. 3 harness connector.
Did the test light illuminate brightly?All
Ye s®Go To 19
No®Repair the Radiator Fan Relay No. 3 Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
19 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 1 harness connector.
Disconnect the Radiator Fan No. 1 harness connector.
Measure the resistance of the Radiator Fan Relay No. 1 Output circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 20
No®Repair the Radiator Fan Relay No. 1 Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
190
DRIVEABILITY - DIESEL
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION ÐContinued

TEST ACTION APPLICABILITY
20 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the Radiator Fan No. 1 harness connector.
Measure the resistance of the Radiator Fan No. 1 Control circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 21
No®Repair the Radiator Fan No. 1 Control circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
21 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the Radiator Fan No. 2 harness connector.
Measure the resistance of the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit from Radiator Fan Relay No. 3.
Is the resistance below 5.0 ohms?All
Ye s®Go To 22
No®Repair the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit from Radiator Fan Relay No. 3 for an open.
Perform ROAD TEST VERIFICATION - VER-2.
22 Turn the ignition off.
Disconnect the Radiator Fan No. 1 harness connector.
Connect a fused jumper wire between the Radiator Fan No. 1 harness connector
cavities.
Turn the ignition on.
With the DRB, actuate the Low Speed Fan Relay.
Did Radiator Fan No. 2 activate on High speed?All
Ye s®Replace Radiator Fan No. 1.
Perform ROAD TEST VERIFICATION - VER-2.
No®Replace Radiator Fan No. 2.
Perform ROAD TEST VERIFICATION - VER-2.
23NOTE: Radiator Fan No. 2 is fed voltage from Radiator Fan Relay No. 3
during low speed operation and then fed voltage from Radiator Fan Relay
No. 2 during high speed operation by a common circuit connected to both
relays.
Turn the ignition off.
Disconnect the Radiator Fan Relay No. 2 harness connector.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the Radiator Fan No. 2 harness connector.
Measure the resistance between ground and the Radiator Fan Relay No. 2 and No. 3
Common Output circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 24
No®Repair the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
191
DRIVEABILITY - DIESEL
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION ÐContinued

TEST ACTION APPLICABILITY
24 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the Radiator Fan No. 1 harness connector.
Using a 12-volt test light connected to 12-volts, check the Radiator Fan No. 1 Control
circuit.
Did the test light illuminate?All
Ye s®Repair the Radiator Fan No. 1 Control circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 25
25 If there are no possible causes remaining, view repair. All
Repair
Replace the Radiator Fan No. 2.
Perform ROAD TEST VERIFICATION - VER-2.
26 Turn the ignition off.
Disconnect the Radiator Fan Relay No. 3 harness connector.
Disconnect the Radiator Fan No. 1 harness connector.
Measure the voltage on the Radiator Fan No. 1 Control circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the Radiator Fan No. 1 Control circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 27
27 If there are no possible causes remaining, view repair. All
Repair
Replace Radiator Fan No. 1.
Perform ROAD TEST VERIFICATION - VER-2.
192
DRIVEABILITY - DIESEL
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION ÐContinued

Symptom:
*CHECKING THE GLOW PLUG OPERATION
POSSIBLE CAUSES
CHECKING THE GLOW PLUGS
FUSED B+ CIRCUIT OPEN
GLOW PLUG RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
GLOW PLUG RELAY OUTPUT CIRCUIT SHORTED TO GROUND
GLOW PLUG RELAY OUTPUT CIRCUIT OPEN
GLOW PLUG RELAY
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Glow Plug harness connectors for all cylinders.
Turn the ignition on.
With the DRB, actuate the Glow Plug Relay.
Using a 12-volt test light connected to ground, probe each Glow Plug harness
connector during actuator test.
Does the test light cycle on and off for each circuit during the actuator test?All
Ye s®Go To 2
No®Go To 3
2 Refer to the Service Information and perform the Glow Plug Test.
Are all Glow Plugs operating properly?All
Ye s®Test Complete.
No®Replace the Glow Plug(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
3NOTE: If the Glow Plug Relay fuse or fuselink is open, refer to the system
schematics for all circuits that are powered by the Glow Plug Relay fuse or
fuselink to determine the cause of the blown fuse/fuselink.
Remove the Glow Plug Relay.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the Glow
Plug Relay connector, cavity 30 in the IPM.
Does the test light illuminate brightly?All
Ye s®Go To 4
No®Repair the Fused B+ (Fuse/Fuselink) circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Disconnect all the Glow Plug harness connectors.
Remove the Glow Plug Relay.
Turn the ignition on.
Measure the voltage on the Glow Plug Relay Output circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the Glow Plug Relay Output circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 5
195
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
5 Turn the ignition off.
Disconnect all the Glow Plug harness connectors.
Remove the Glow Plug Relay.
Measure the resistance between ground and the Glow Plug Relay Output circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 6
No®Repair the Glow Plug Relay Output circuit for a short to ground.
Inspect the fuse or fuselink and replace as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Disconnect all the Glow Plug harness connectors.
Remove the Glow Plug Relay.
Connect a jumper wire across Glow Plug Relay connector cavities 30 and 87.
Using a 12-volt test light connected to ground, check the Glow Plug Relay Output
circuit at each Glow Plug harness connector.
Is the test light on at each Glow Plug harness connector?All
Ye s®Go To 7
No®Repair the Glow Plug Relay Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7 Refer to the Service Information and perform the Glow Plug Test.
Are all Glow Plugs operating properly?All
Ye s®Go To 8
No®Replace the Glow Plug(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
8 If there are no possible causes remaining, view repair. All
Repair
Replace the Glow Plug Relay.
Perform ROAD TEST VERIFICATION - VER-2.
196
DRIVEABILITY - DIESEL
*CHECKING THE GLOW PLUG OPERATION ÐContinued

Symptom:
*CHECKING THE LIFT PUMP MOTOR OPERATION
POSSIBLE CAUSES
LIFT PUMP OUTPUT TEST
FUSED B+ CIRCUIT OPEN
LIFT PUMP RELAY
LIFT PUMP RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
LIFT PUMP RELAY OUTPUT CIRCUIT SHORTED TO GROUND
LIFT PUMP RELAY OUTPUT CIRCUIT OPEN
LIFT PUMP GROUND CIRCUIT OPEN
LIFT PUMP MOTOR
TEST ACTION APPLICABILITY
1NOTE: If any Fuel Lift Pump DTCs are present, diagnose the DTCs first.
Turn the ignition on.
With the DRB, actuate the Lift Pump Relay.
Gain access to the Lift Pump Motor to determine if it is cycling on and off.
Does the Lift Pump Motor cycle on and off?All
Ye s®Go To 2
No®Go To 3
2NOTE: The Lift Pump fuel output must be sufficient to prime the Injector
Pump.
Refer to the Service Information to test the Lift Pump pressure and volume output.
Did the Lift Pump pass the Lift Pump pressure and volume test?All
Ye s®Test Complete.
No®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
3NOTE: If the Lift Pump Relay fuse is open, refer to the system schematics
for all circuits that are powered by the Lift Pump Relay fuse to determine
the cause of the blown fuse.
Remove the Lift Pump Relay from the IPM.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the Lift
Pump Relay connector in the IPM.
Does the test light illuminate brightly?All
Ye s®Go To 4
No®Repair the Fused B+ (Fuse) circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
197
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Install a substitute relay in place of the Lift Pump Relay.
Turn the ignition on.
With the DRB, actuate the Lift Pump Relay.
Does the Lift Pump Motor cycle on and off?All
Ye s®Replace the Lift Pump Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 5
5 Turn the ignition off.
Disconnect the Lift Pump Motor harness connector.
Remove the Lift Pump Relay.
Turn the ignition on.
Measure the voltage on the Lift Pump Relay Output circuit.
Is the voltage above 1.0 volt?All
Ye s®Repair the Lift Pump Relay Output circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 6
6 Turn the ignition off.
Disconnect the Lift Pump Motor harness connector.
Remove the Lift Pump Relay.
Measure the resistance between ground and the Lift Pump Relay Output circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 7
No®Repair the Lift Pump Relay Output circuit for a short to ground.
Inspect the fuse and replace as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
7 Turn the ignition off.
Disconnect the Lift Pump Motor harness connector.
Remove the Lift Pump Relay.
Connect a jumper wire across Lift Pump Relay connector cavities 30 and 87.
Using a 12-volt test light connected to ground, check the Lift Pump Relay Output
circuit.
Is the test light illuminated brightly?All
Ye s®Go To 8
No®Repair the Lift Pump Relay Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
8 Turn the ignition off.
Disconnect the Lift Pump Motor harness connector.
Using a 12-volt test light connected to 12-volts, check the Lift Pump Ground circuit.
Is the test light illuminated brightly?All
Ye s®Go To 9
No®Repair the Lift Pump Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
198
DRIVEABILITY - DIESEL
*CHECKING THE LIFT PUMP MOTOR OPERATION ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the Vehicle Speed Sensor harness connector.
Turn the ignition on.
Measure the voltage of the Ignition Switch Output circuit in the Vehicle Speed Sensor
harness connector.
Is the voltage above 10.0 volts?All
Ye s®Go To 5
No®Repair the Ignition Switch Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the Vehicle Speed Sensor harness connector.
Turn the ignition on.
Measure the voltage of the Vehicle Speed Sensor Signal circuit.
Is the voltage above 5.5 volts?All
Ye s®Go To 6
No®Go To 8
6 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Vehicle Speed Sensor harness connector.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ECM/PCM Relay
connector.
Turn the ignition on.
Measure the voltage of the Vehicle Speed Sensor Signal circuit.
Is the voltage below 1.0 volt?All
Ye s®Go To 7
No®Repair the Vehicle Speed Sensor Signal circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
7 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
8 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Vehicle Speed Sensor harness connector.
Measure the resistance between ground and the Vehicle Speed Sensor Signal circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 9
No®Repair the Vehicle Speed Sensor Signal circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
205
DRIVEABILITY - DIESEL
*CHECKING THE VEHICLE SPEED SIGNAL ÐContinued