relay CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
11 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the IPM C2 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit between the IPM
harness connector and the Radiator Fan Relay harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 12
No®Repair the Radiator Fan Relay Control circuit for an open
between the Radiator Fan Relay harness connector and the IPM
harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
12 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the IPM C3 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit between the IPM
harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Repair the Radiator Fan Relay Control circuit for an open
between PCM harness connector and the IPM harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
213
DRIVEABILITY - GAS
P1491-RAD FAN CONTROL RELAY CIRCUIT ÐContinued

Symptom:
*CHECKING FUEL DELIVERY
POSSIBLE CAUSES
FUEL PUMP RELAY
FUEL PRESSURE OUT OF SPECS
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
FUEL PUMP CAPACITY (VOLUME) OUT OF SPECS
FUEL PUMP RELAY FUSED B+ CIRCUIT
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN/HIGH RESISTANCE
IPM FUSE & RELAY CENTER
FUEL PUMP MODULE
TEST ACTION APPLICABILITY
1NOTE: Inspect the Fuel Pump Relay fuse located in the IPM. If the Fuel
Pump Relay fuse is open, repair the cause of the open first before continu-
ing. Inspect the Fuel Pump Relay Output circuit for a short to ground for
the cause of the open fuse.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Note: It may be necessary to use a mechanics stethoscope in the next step.
Listen for fuel pump operation at the fuel tank.
Does the Fuel Pump operate?All
Ye s®Go To 2
No®Go To 6
Caution: Stop All Actuations.
227
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
5Note: The fuel pressure must be within specification before continuing.
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Disconnect the fuel supply line at the fuel rail.
Connect fuel line adapter #6539(5/169) or #6631(3/89) to the disconnected fuel supply
line. Insert the other end of the adapter into a graduated container.
Caution: Do not operate the fuel pump for more than 7 seconds in the next
step. Fuel pump module reservoir may run empty and damage to the fuel
pump will result.
Note: Specification: A good fuel pump will deliver at least 1/4 liter (1/2 pint)
of fuel in 7 seconds.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test for 7 seconds.
Is the fuel pump capacity within specification?All
Ye s®Test Complete.
No®Check for a kinked/damaged fuel supply line between the fuel
tank and fuel rail. If OK, replace the fuel pump module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
Caution: Stop All Actuations.
6 Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Using a 12 volt test light connected to ground, probe the Fuel Pump Relay Output
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 7
No®Go To 9
Caution: Stop All Actuations.
7 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Note: Check connectors - It is critical that the connector is free from any
signs of corrosion or deformities - Clean/repair as necessary.
Using a test light connected to battery voltage, probe the Fuel Pump ground circuit
at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 8
No®Repair the open/high resistance in the fuel pump ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
8 If there are no possible causes remaining, view repair. All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
229
DRIVEABILITY - GAS
*CHECKING FUEL DELIVERY ÐContinued

TEST ACTION APPLICABILITY
9 Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
With a 12 volt test light connected to ground, probe the Fuel Pump Relay Fused B+
circuit at the IPM.
Does the test light illuminate?All
Ye s®Go To 10
No®Check for an open Fuel Pump fuse, repair cause of open. If OK,
replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
10 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Disconnect the IPM C8 harness connector.
Measure the resistance of the Fuel Pump Relay Output circuit from between the IPM
harness connector and the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 11
No®Repair the Fuel Pump Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER-1.
11NOTE: Ensure all IPM harness connectors are connected.
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Remove the Fuel Pump Relay from the IPM.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM and
the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the Fuel Pump Relay.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
230
DRIVEABILITY - GAS
*CHECKING FUEL DELIVERY ÐContinued

Symptom:
*CHECKING RADIATOR FAN RELAY OUTPUT
POSSIBLE CAUSES
RADIATOR FAN RELAY OPERATION
GROUND CIRCUIT OPEN
RADIATOR FAN RELAY OUTPUT CIRCUIT
RADIATOR FAN ASSENBLY
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Using a jumper wire, momentarily jumper the Fuse B+ circuit and Radiator Fan
Relay Output circuit in the Radiator Fan Relay harness connector.
Are both Fans operating?All
Ye s®The Radiator Fan System operating properly at this time.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Go To 2
2 Turn the ignition off.
Disconnect the Radiator Fan harness connector.
Measure both Ground circuit in the Radiator Fan Motor harness connectors to
ground.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Repair the Ground circuit(s) for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
3 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect both Radiator Fan Motor harness connectors.
Using a jumper wire, jumper the Fused B+ circuit and the Radiator Fan Output
circuit in the Radiator Fan Relay harness connector.
Measure the voltage in both Radiator Fan Motor harness connectors.
Is the voltage above 10 volts?All
Ye s®Replace the Radiator Fan Assembly.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Repair the Radiator Fan Relay Output circuit(s) for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
235
DRIVEABILITY - GAS

Symptom:
*CHECKING THE A/C RELAY OUTPUT
POSSIBLE CAUSES
A/C CLUTCH RELAY OPERATION
GROUND CIRCUIT OPEN
A/C CLUTCH
FUSED B+ CIRCUIT
A/C CLUTCH OUTPUT CIRCUIT
IPM FUSE & RELAY CENTER
A/C CLUTCH RELAY
TEST ACTION APPLICABILITY
1NOTE: Ensure that the refrigerant system is properly charged. Refer to the
appropriate Service Information.
Turn the ignition on.
With the DRBIIIt, actuate the A/C Clutch Relay.
Is the A/C Clutch actuating?All
Ye s®The A/C Clutch System operating properly at this time.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Go To 2
2 Turn the ignition off.
Disconnect the A/C Clutch harness connector.
Measure the Ground circuit in the A/C Clutch harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Repair the Ground circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
3 Disconnect the A/C Clutch harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the A/C Clutch Relay.
Measure the voltage of the A/C Clutch Relay Output circuit in the A/C Clutch harness
connector.
Is the voltage above 11.0 volts?All
Ye s®Replace the A/C Clutch.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Go To 4
236
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the IPM.
Does the test light illuminate brightly?All
Ye s®Go To 5
No®Check for an open A/C Clutch fuse, repair the cause of the open
fuse. If OK, replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
5 Turn the ignition off.
Disconnect the IPM C3 harness connector.
Disconnect the A/C Clutch harness connector.
Measure the resistance of the A/C Clutch Relay Output circuit between the IPM
harness connector and the A/C Clutch harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the A/C Clutch Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
6NOTE: Ensure all IPM harness connectors are connected.
Turn the ignition off.
Disconnect the A/C Clutch harness connector.
Remove the A/C Clutch Relay from the IPM.
Measure the resistance of the A/C Clutch Relay Output circuit between the IPM and
the A/C Clutch harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the A/C Clutch Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
237
DRIVEABILITY - GAS
*CHECKING THE A/C RELAY OUTPUT ÐContinued

Symptom:
P0645-A/C CLUTCH RELAY CKT
When Monitored and Set Condition:
P0645-A/C CLUTCH RELAY CKT
When Monitored: With the ignition on. Battery voltage greater than 10 volts. A/C Switch
on.
Set Condition: An open or shorted condition is detected in the A/C clutch relay control
circuit.
POSSIBLE CAUSES
A/C CLUTCH RELAY INTERMITTENT OPERATION
INTERMITTENT CONDITION
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
INTELLIGENT POWER MODULE
A/C CLUTCH RELAY
IPM FUSE & RELAY CENTER
A/C CLUTCH RELAY CONTROL CKT OPEN
A/C CLUTCH RELAY CONTROL CIRCUIT SHORT TO GROUND
PCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, actuate the A/C Clutch Relay.
Is the A/C Clutch Relay operating?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition on.
With the DRBIIIt, actuate the A/C Clutch Relay.
Wiggle the wiring harness from the A/C Clutch Relay to the PCM while the relay is
actuating.
Did the A/C Clutch Relay stop when wiggling the wiring harness?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
239
HEATING & A/C

TEST ACTION APPLICABILITY
3WARNING: KEEP CLEAR OF THE ENGINE'S MOVING PARTS.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DRB Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
4 Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 5
No®Go To 10
5 Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the A/C Clutch Relay circuit in
the IPM.
With the DRBIIIt, actuate the A/C Clutch Relay.
Does the test light flash on and off?All
Ye s®Replace the A/C Clutch Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 6
6 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the A/C Clutch Relay Control
circuit in the IPM harness connector.
With the DRBIIIt, actuate the A/C Clutch Relay.
Does the test light flash on and off?All
Ye s®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 7
240
HEATING & A/C
P0645-A/C CLUTCH RELAY CKT ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the A/C Clutch Relay Control circuit between the
Intelligent Power Module C3 harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 8
No®Repair the A/C Clutch Relay Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
8 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Fuel Pump Relay Control circuit in the Intelligent
Power Module C3 harness connector to ground.
Is the resistance below 5.0 ohms.All
Ye s®Repair the A/C Clutch Relay Control circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 9
9 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module Module in
accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
10 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM harness connector.
Does the test light illuminate?All
Ye s®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
241
HEATING & A/C
P0645-A/C CLUTCH RELAY CKT ÐContinued