CHRYSLER VOYAGER 1996 Service Manual

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT1. Erratic Message from
another Module.1. (a) Check the BCM using a scan tool If OK, go to
Step (b). If not OK, refer to the BCM section of the
service manual to repair the BCM.
(b) Check the PCM using a scan tool. If OK, go to Step
(c). If not OK, refer to the PCM section of the service
manual to repair the PCM.
(c) Check the speed signal input into the PCM. The
speed signal originates from one of the following
sources:
²A distance sensor for vehicles with 3 speed automatic
transmission. Check continuity from distance sensor to
PCM. If OK, replace distance sensor. If not OK, repair
wiring.
²The Electronic Transmission Control Module (TCM)
vehicles with the 4 speed electronic transmissions.
Check continuity from TCM to engine controller. If OK,
use a scan tool to check TCM. Refer to the electronic
section of the service manual to repair the TCM. If not
OK, repair wiring.
2. Internal Cluster Failure. 2. (a) Perform cluster self diagnostic test and check for
fault codes.
²If the pointer moves during test but still appears
erratic and fault codes 110 or 111 don't appear in the
odometer display, then go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (e).
²If fault code 111 appears in the odometer display go
to Step (d).
²If fault codes 905, 920, or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault and repair module.
(b) Replace cluster subdial assembly. To Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the speedometer failure.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 5
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
SPEEDOMETER
INACCURATE.1. Speedometer Out of
Calibration.1. (a) Perform Cluster Self Diagnostic Test.
²If speedometer is accurate to the calibration points
then look for another possible cause of inaccuracy.
²If speedometer is not accurate to the calibration
points, go to Step (b).
(b) Use a scan tool to calibrate speedometer.
2. Wrong Speedometer
Pinion Size For Tire Size.2. (a) If vehicle has a 4 speed electronic transmission
go to Step (c). Otherwise go to Step (b).
(b) Check if correct speedometer pinion is being used
with tires on vehicle. Refer to transmission section of
manual for test and repair procedure.
²If the incorrect pinion is in transmission then replace
with correct pinion.
²If the correct pinion is in the transmission calibrate
speedometer using a scan tool to correct for the
inaccuracy.
(c) use a scan tool to check the TCM to see if the
correct tire size has been programmed into the TCM.
²If the incorrect tire size was selected, select the
proper tire size.
²If the correct tire size was selected, calibrate
speedometer to correct for the inaccuracy.
3. Bad Speed Sensor. 3. Refer to the proper section of the service manual for
test and repair procedure.
8E - 6 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

TACHOMETER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT1. Internal Cluster Failure. 1. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If tachometer pointer moves to calibration points
during test and fault codes 110 or 111 don't appear in
the odometer display then failure is not in the cluster.
Look for another possible cause of failure.
²If the pointer doesn't move during test, go to Step
(b).
²If fault code 110 is displayed in the odometer, go to
Step (b).
²If fault code 111 is displayed in the odometer then go
to Step (f).
²If fault codes 920 or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault an repair module.
(b) Replace main cluster pc board. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
(e) Replace subdial assembly and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the tachometer failure.
(f) Use a scan tool to calibrate tachometer and perform
Self Diagnostic Test. If OK, stop. If not OK, go to Step
(b).
2. No rpm CCD Bus
Message or Zero rpm
CCD Bus Message from
Engine Controller.2. Check the PCM using a scan tool. Refer to the PCM
section of the manual to properly diagnose and repair.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 7
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT.1. Bad CCD Bus
Message from Engine
Controller.1. Check the PCM using a scan tool. Refer to the PCM
section of the manual to properly diagnose and repair.
2. Internal Cluster Failure. 2. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If the pointer moves during test but still appears
erratic and fault codes 110 or 111 don't appear in the
odometer display, go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (e).
²If fault code 111 appears in the odometer display go
to Step (d).
²If fault codes 920 or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault and repair module.
(b) Replace cluster subdial assembly. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
(e) Replace main cluster pc board and use a scan tool
to calibrate cluster. If not OK, look at another possible
cause for the tachometer failure.
TACHOMETER
INACCURATE.1. Tachometer out of
calibration.1. Calibrate tachometer using a scan tool.
8E - 8 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

FUEL GAUGE DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT.1. Internal cluster failure. 1. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If fuel gauge pointer moves to calibration points during
test and fault codes 110 or 111 don't appear in the
odometer display then failure is not in the cluster. Look
for another possible cause of failure.
²If the pointer doesn't move during test, go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (b).
²If fault code 111 is displayed in the odometer then go
to Step (f).
²If fault code 920 is displayed in the odometer refer to
the fault code chart to identify which module is causing
the fault and repair module.
(b) Replace main cluster pc board. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
(e) Replace subdial assembly and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the fuel gauge failure.
(f) Use a scan tool to calibrate fuel gauge and perform
Self Diagnostic Test. If OK, stop. If not OK, go to Step
(b).
2. No CCD Fuel Message
or Empty CCD Bus
Message from Body
Controller.2. (a) Check the BCM using a scan tool. If OK, go to
Step (b). If not OK, refer to the BCM section of the
manual to properly diagnose and repair.
(b) Refer to the Fuel section of the service manual for
the fuel level sending unit test procedure. Test unit and
repair as instructed.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 9
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT.1. Bad CCD Fuel
Message from the Body
Controller.1. (a) Use a scan tool to check the BCM. If OK, go to
Step (b). If not OK, refer to the BCM section of the
service manual to properly diagnose and repair.
(b) Refer to the Fuel section of the service manual for
the fuel level sending unit test procedure. Test unit. If
OK, look for another possible cause for fuel gauge
failure. If not OK, repair sending unit.
2. Internal Cluster Failure. 2. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If the pointer moves during test but still appears
erratic and fault codes 110 or 111 don't appear in the
odometer display, go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (e).
²If fault code 111 appears in the odometer display to
Step (d).
²If fault code 920 is displayed in the odometer refer to
the fault code chart to identify which module is causing
the fault and repair module.
(b) Replace cluster subdial assembly. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
(e) Replace main cluster pc board and use a scan tool
to calibrate cluster. If not OK, look at another possible
cause for the fuel gauge failure.
FUEL GAUGE
INACCURATE.1. Fuel Gauge Out of
Calibration.1. (a) Perform Cluster Self Diagnostic Test. If pointer is
accurate to the calibration points look for another
possible cause of failure. If pointer is inaccurate to the
calibration points, to Step (b).
(b) Use a scan tool to calibrate fuel gauge.
2. Fuel Level Sending
Unit is Out of Calibration.2. (a) Refer to the Fuel section of the service manual
for test and repair procedure.
U
8E - 10 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

TEMPERATURE GAUGE DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT1. Internal Cluster Failure. 1. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If temperature gauge pointer moves to calibration
points during test and fault codes 110 or 111 don't
appear in the odometer display then failure is not in the
cluster. Look for another possible cause of failure.
²If the pointer doesn't move during test, go to Step
(b).
²If fault code 110 is displayed in the odometer, go to
Step (b).
²If fault code 111 is displayed in the odometer then go
to Step (f).
²If fault codes 920 or 940 are displayed refer to the
fault code chart to identify which module is causing the
fault and repair module.
(b) Replace main cluster pc board. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
(e) Replace subdial assembly and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the temperature gauge failure.
(f) Use a scan tool to calibrate temperature gauge and
perform Self Diagnostic Test. If OK, stop. If not OK, go
to Step (b).
2. No CCD Temperature
Message or Cold CCD
Bus Message from the
Body Control Module.2. (a) Check BCM fault codes using a scan tool. If
there are not faults, go to Step (b). If there are faults,
refer to the BCM section of the manual to properly
diagnose and repair.
(b) Check PCM fault codes using a scan tool. If there
are no faults, go to Step (c). If there are faults, refer to
the PCM section of the manual to properly diagnose
and repair.
(c) Refer to the coolant sensor section of the service
manual for the coolant sensor test procedure. Repair
sensor as needed.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 11
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT.1. Bad CCD Bus
Message from the Body
Control Module.1. (a) Check BCM fault codes using a scan tool. If
there are no faults, go to Step (b). If there are faults,
refer to the BCM section of the manual to properly
diagnose and repair.
(b) Check PCM fault codes using a scan tool. If there
are no faults, go to Step (c). If there are faults, refer to
the PCM section of the manual to properly diagnose
and repair.
(c) Refer to the coolant sensor section of the service
manual for the coolant sensor test procedure. Repair
sensor as needed.
2. Internal Cluster Failure. 2. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If the pointer moves during test but still appears
erratic and fault codes 110 or 111 don't appear in the
odometer display, go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (e).
²If fault code 111 appears in the odometer display go
to Step (d).
²If fault code 920 or 940 is displayed refer to the fault
code chart to identify which mode is causing the fault
and repair module.
(b) Replace cluster subdial assembly. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. DO NOT COMPLETELY INSTALL
CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS
CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go Step (e).
(e) Replace main cluster pc board and use a scan tool
to calibrate cluster. If not OK, look at another possible
cause for the temperature gauge failure.
TEMPERATURE GAUGE
INACCURATE.1. Temperature Gauge
Out of Calibration.1. (a) Perform Cluster Self-Diagnostic Test.
²If pointer is accurate to the calibration points look for
another possible cause of failure.
²If pointer is inaccurate to the calibration points, go
the Step (b).
(b) Use a scan tool to calibrate temperature gauge.
2. Coolant Sensor Out of
Calibration.2. Refer to the Cooling section of the service manual
for test and repair procedure.
8E - 12 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

ODOMETER DIAGNOSIS
CONDITIONPOSSIBLE
CAUSESCORRECTION
NO DISPLAY 1. No CCD
Odometer Bus
Message from Body
Control Module.1. Use a scan tool to check the BCM. Refer to the BCM section of
the manual to properly diagnose and repair.
2. Internal Cluster
Failure.2. (a) Perform Cluster Self Diagnostic Test and check for fault
codes.
²If odometer passes the dim test and segment check and
fault codes 110 or 111 don't appear in the odometer display
then failure is not in the cluster. Look for another possible
cause of failure.
²If odometer doesn't work go to Step (b).
²If fault code 110 is displayed in the odometer, go to Step (b).
²If fault code 920 or 921 is displayed use a scan tool to check
BCM.
(b) Remove cluster from instrument panel and verify that
odometer assembly is properly connected to main pc board. If
OK, go to Step (c). If not OK, reconnect odometer assembly to
main pc board.
(c) Replace odometer assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness.
Place it back into the proper position in the instrument panel.
DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT
PANEL UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If
not OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible cause for
the odometer failure.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 13
DIAGNOSIS AND TESTING (Continued)

CONDITIONPOSSIBLE
CAUSESCORRECTION
ERRATIC DISPLAY 1. Internal Cluster
Failure.1. (a) Perform Cluster Self Diagnostic Test and check for fault
codes.
²If odometer passes the dim test and segment check and fault
codes 110 or 111 don't appear in the odometer displayed then
failure is not in the cluster. Look for another possible cause of
failure.
²If odometer doesn't work go to Step (b).
²If fault code 110 is displayed in the odometer, go to Step (b).
²If fault code 920 or 921 is displayed use a scan tool to check
BCM.
(b) Remove cluster from instrument panel and verify that odometer
assembly is properly connected to main pc board. If OK, go to
Step (c). If not OK, reconnect odometer assembly to main pc
board.
(c) Replace odometer assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness. Place it
back into the proper position in the instrument panel. DO NOT
COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL
UNTIL UNIT TESTED. Go to Step (e).
(e) Perform Self diagnostic Test. If OK, continue installation. If not
OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the odometer
failure.
2. Bad CCD Bus
Message from Body
Controller Module.2. Use a scan tool to check the BCM. Refer to the BCM section of
the manual to properly diagnose and repair.
ODOMETER WON'T
GO INTO TRIP
MODE.1. Trip Switch
Doesn't Work.1. Use a scan tool to perform trip switch activation test. If OK, look
for another possible cause of failure. If not OK, replace odometer
assembly.
TRIP ODOMETER
WON'T RESET.1. Reset Switch
Doesn't Work.1. Use a scan tool to perform reset switch activation test. If OK,
look for another possible cause of failure. If not OK, replace
odometer assembly.
8E - 14 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)