ignition relay CHRYSLER VOYAGER 2000 Diagnostic Manual

TEST ACTION APPLICABILITY
30 Ignition On, Engine Not Running.
With the DRB, actuate Ignition Coil #1.
With a Voltmeter, measure the ASD Relay Output Circuit.
Is the voltage above 10 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Replace Ignition Coil.
Perform Powertrain Verification Test VER-1A.
No®Go To 31
31 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Using a Jumper Wire connect the ASD Relay Output Circuit to Ground at the
Ignition Coil Connector.
With an Ohmmeter, measure the ASD Relay Output Circuit for resistance to ground
at the Relay.
Is the resistance below 5.0 ohms?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Go To 32
No®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
32 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit, cavity B in ASD Relay Connector.
Is the Voltage above 10 volts?ENGINE - 2.0L,
2.4L I-4 DOHC
and/or ENGINE -
3.3L V6 and/or EN-
GINE - 3.8L V6
and/or ENGINE -
3.3L V6 FFV
Ye s®Replace the Auto Shutdown Relay.
Perform Verification Test VER-1A
No®Repair open Fused B(+).
Perform Verification TEST VER-1A
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* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
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Symptom:
* NO CRANK CONDITION
POSSIBLE CAUSES
BATTERY CIRCUIT RESISTANCE TOO HIGH
FUSED B(+) CIRCUIT OPEN
STARTER RELAY CONTROL CIRCUIT OPEN
STARTER RELAY OUTPUT CIRCUIT OPEN
CRANKSHAFT NOT ABLE TO ROTATE
STARTER MOTOR DEFECTIVE
PCM DEFECTIVE (NO CRANK CONDITION)
STARTER RELAY DEFECTIVE (RESISTANCE <=100 OHMS)
STARTER RELAY DEFECTIVE (RESISTANCE ABOVE 100 OHMS)
IGNITION SWITCH OUTPUT CIRCUIT OPEN
PARK/NEUTRAL SWITCH DEFECTIVE
TEST ACTION APPLICABILITY
1Note: Ensure the SKIM has proper communication and that there are no
SKIM DTC's present before continuing.
Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Warning: The Transmission must be in Park and the Parking Brake must be
on for the next step.
Warning: The engine may be cranked in the next step. Keep away from
moving parts.
Briefly connect a jumper wire between Starter Relay Output and Fused B(+)
Circuits.
Did the Starter Motor crank the Engine?All
Ye s®Go To 2
No®Go To 9
2 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit.
Is the voltage above 11.6 volts?All
Ye s®Go To 3
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
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STARTING
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TEST ACTION APPLICABILITY
3 Ignition Off.
Ensure the Transmission is in Park.
With the DRB, read the Park/Neutral Position Switch.
Does the Switch show Park?All
Ye s®Go To 4
No®Repair Park/Neutral Switch.
Perform Powertrain Verification Test VER-1A.
4 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, test the Starter Relay Terminals for resistance.
Is the resistance above 100 ohms?All
Ye s®Replace the Starter Relay.
Perform Powertrain Verification Test VER-1A.
No®Go To 5
5 Ignition Off
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a voltmeter, probe Ignition Switch Output Circuit.
While attempting to crank the engine, read the Voltmeter.
Is the voltage above 10 volts?All
Ye s®Go To 6
No®Repair the open Ignition Switch Output (Start) Circuit.
Perform Powertrain Verification Test VER-1A.
6 Ignition Off.
Disconnect the Starter Relay Connector.
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
With an ohmmeter, test the Starter Relay Control Circuit for resistance.
Is the resistance above 5.0 ohms?All
Ye s®Repair the open Starter Relay Control Circuit.
Perform Powertrain Verification Test VER-1A.
No®Go To 7
7 Ignition Off
Disconnect the Powertrain Control Module.
Note: Check connectors - Clean/repair as necessary.
Warning: The Transmission must be in park and the Parking Brake must be
on for the next step.
Warning: The Engine may be cranked in the next step. Keep away form
moving Engine parts.
Connect a jumper wire between the Starter Relay Control Circuit and ground.
Briefly turn the Ignition to the crank position and then release.
Did the Engine crank?All
yes
Go To 8
no
Replace the Starter Relay.
Perform Powertrain Verification Test VER-1A.
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* NO CRANK CONDITION ÐContinued
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TEST ACTION APPLICABILITY
8 If there are no potential causes remaining, the Powertrain Control Module is
assumed to be defective.
View repair options.All
Repair
Replace the Powertrain Control Module.
Perform Powertrain Verification Test VER-1A.
9 Ignition Off.
Ensure the Transmission is in Park.
With the DRB, read the Park/Neutral Position Switch.
Does the Switch show Park?All
Ye s®Go To 10
No®Repair Park/Neutral Switch.
Perform Powertrain Verification Test VER-1A.
10 Ignition Off
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Warning: The Engine may be cranked in the next step. Keep away from
moving parts.
Warning: The engine may be cranked in the next step. Keep away from
moving parts.
Briefly connect a jumper wire between Starter Relay Output and Fused B(+)
Circuits.
Did the Starter Solenoid click when the jumper wire was connected?All
Ye s®Go To 11
No®Go To 15
11 Ignition Off
Check the Battery Cables for high resistance. (Use Service Manual procedure.)
Did either Battery Circuit have a voltage drop greater than 0.2 volt?All
Ye s®Repair the Battery Circuit for high resistance.
Perform Powertrain Verification Test VER-1A.
No®Go To 12
12 Ignition Off
Attempt to manually rotate the Crankshaft 360 degrees.
Is the Crankshaft able to rotate 360 degrees?All
Ye s®Go To 13
No®Repair the Engine mechanical problem as necessary.
Perform Powertrain Verification Test VER-1A.
13 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit.
Is the voltage above 11.6 volts?All
Ye s®Go To 14
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
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* NO CRANK CONDITION ÐContinued
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TEST ACTION APPLICABILITY
14 Ignition Off.
Disconnect Starter Relay Output Wire from the Starter Solenoid.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure Starter Relay Output Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 19
No®Repair open Starter Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
15 Ignition Off
Check the Battery Cables for high resistance. (Use Service Manual procedure.)
Did either Battery Circuit have a voltage drop greater than 0.2 volt?All
Ye s®Repair the Battery Circuit for high resistance.
Perform Powertrain Verification Test VER-1A.
No®Go To 16
16 Ignition Off
Attempt to manually rotate the Crankshaft 360 degrees.
Is the Crankshaft able to rotate 360 degrees?All
Ye s®Go To 17
No®Repair the Engine mechanical problem as necessary.
Perform Powertrain Verification Test VER-1A.
17 Ignition Off.
Disconnect Starter Relay Output Wire from the Starter Solenoid.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
Using an ohmmeter, measure Starter Relay Output Circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 18
No®Repair open Starter Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
18 Ignition Off.
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a Voltmeter, measure the Fused B(+) Circuit.
Is the voltage above 11.6 volts?All
Ye s®Go To 19
No®Repair open Fused B(+) Circuit. (check Ignition Switch Fuse in
PDC).
Perform Powertrain Verification Test VER-1A.
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* NO CRANK CONDITION ÐContinued
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TEST ACTION APPLICABILITY
19 Ignition Off
Disconnect the Starter Relay Connector.
Note: Check connectors - Clean/repair as necessary.
With a voltmeter, probe Ignition Switch Output Circuit.
While attempting to crank the engine, read the Voltmeter.
Is the voltage above 10 volts?All
Ye s®Go To 20
No®Repair the open Ignition Switch Output (Start) Circuit.
Perform Powertrain Verification Test VER-1A.
20 If there are no potential causes remaining, the Starter Motor is assumed to be
defective.
View repair options.All
Repair
Replace the Starter Motor.
Perform Powertrain Verification Test VER-1A.
300
STARTING
* NO CRANK CONDITION ÐContinued
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BRAKE SHIFT INTERLOCK SOLENOID (EXCEPT BUILT-UP EXPORT)-2WAYCAV CIRCUIT FUNCTION
1 K29 20WT/PK RED BRAKE WARNING LAMP DRIVER
2 F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF)
CAMSHAFT POSITION SENSOR - BLACK 3-WAYCAV CIRCUIT FUNCTION
1 K7 18OR 8V SUPPLY
2 K4 18BK/LB SENSOR GROUND
3 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
CLOCKSPRING C1 - YELLOW 2 WAYCAV CIRCUIT FUNCTION
1 R43 18BK/LB DRIVER AIRBAG LINE 1
2 R45 18DG/LB DRIVER AIRBAG LINE 2
CLOCKSPRING C2 - NATURAL 5 WAYCAV CIRCUIT FUNCTION
1 X3 20BK/RD HORN RELAY CONTROL SENSE
2 X10 20RD/WT (RADIO RE-
MOTE CONTROL)RADIO MUX
3 Z2 20BK/LG (SPEED CON-
TROL)GROUND
4 V37 20RD/LG (SPEED
CONTROLSPEED CONTROL SWITCH SIGNAL
5 X20 20RD/BK (RADIO RE-
MOTE CONTROL)RADIO CONTROL MUX
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CONNECTOR PINOUTS
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IDLE AIR CONTROL MOTOR - BLACK 4 WAYCAV CIRCUIT FUNCTION
1 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
3 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
4 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
IGNITION COIL PACK (2.0L/2.4L) - BLACK 3 WAYCAV CIRCUIT FUNCTION
1 K17 18DG/TN IGNITION COIL NO. 2 DRIVER
2 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K19 18GY/RD IGNITION COIL NO. 1 DRIVER
IGNITION COIL PACK (3.3L/3.8L) - BLACK 4 WAYCAV CIRCUIT FUNCTION
1 K17 18DB/TN (3.3L) IGNITION COIL NO 2 DRIVER
1 K18 18RD/YL (3.8L) IGNITION COIL NO 3 DRIVER
2 A142 18DG/OR (3.3L) AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K19 18GY/RD (3.8L) IGNITION COIL NO 1 DRIVER
3 A142 18DG/OR (3.8L) AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K19 18GY/RD (3.3L) IGNITION COIL NO 1 DRIVER
4 K17 18DB/TN (3.8L) IGNITION COIL NO 2 DRIVER
4 K18 18RD/YL (3.3L) IGNITION COIL NO 3 DRIVER
INSTRUMENT CLUSTER - BLACK 13 WAYCAV CIRCUIT FUNCTION
1- -
2 M1 20PK FUSED B(+)
3- -
4- -
5- -
6 E2 20OR PANEL LAMPS FEED
7 Z2 20BK/LG GROUND
8- -
9 D2 20WT/BK CCD BUS (-)
10 D1 20VT/BR CCD BUS (+)
11 F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF)
12 - -
13 Z1 20BK GROUND
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CONNECTOR PINOUTS
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OXYGEN SENSOR 1/2 DOWNSTREAM - BLACK 4 WAYCAV CIRCUIT FUNCTION
1 Z12 20BK GROUND
2 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K127 20BK/LB OXYGEN SENSOR GROUND
4 K141 20TN/WT OXYGEN SENSOR 1/2 SIGNAL
PARK/NEUTRAL POSITION SWITCH (ATX) - BLACK 3 WAYCAV CIRCUIT FUNCTION
1 L1 18VT/BK BACK-UP LAMP FEED
2 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
3 F20 18WT FUSED IGNITION SWITCH OUTPUT (RUN)
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CONNECTOR PINOUTS
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FUSESFUSE
NO.AMPS FUSED CIRCUIT FEED CIRCUIT
1 15A INTERNAL A0 6RD
2 20A (GAS/EATX) INTERNAL A0 6RD
3 20A INTERNAL A0 6RD
4 10A INTERNAL A0 6RD
5 10A INTERNAL A0 6RD
6 15A F41 20PK/VT A0 6RD
7 20A INTERNAL A0 6RD
8 20A L43 18VT INTERNAL
9 15A L44 20VT/RD INTERNAL
10 25A A20 12RD/DB A0 6RD
11 20A F32 18PK/DB A0 6RD
12 10A A22 12BK/OR F23 18DB/YL
13 10A F14 18LG/YL INTERNAL
14 20A L9 18BK/VT A0 6RD
15 10A M1 20PK A0 6RD
16 - SPARE A0 6RD
17 - SPARE A0 6RD
18 10A L33 20RD INTERNAL
19 10A L34 20RD/OR A0 6RD
19 10A L34 20RD/OR A0 6RD
101 40A INTERNAL A0 6RD
102 40A A10 12RD/DG A0 6RD
103 40A A2 12PK/BK A0 6RD
104 40A A1 12RD A0 6RD
105 40A (DIESEL) A17 12RD/BK A0 6RD
106 40A A16 12GY A0 6RD
107 40A INTERNAL A0 6RD
108 40A A4 12BK/RD A0 6RD
109 30A INTERNAL A0 6RD
A/C COMPRESSOR CLUTCH RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL (GAS)
85 C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL (DIESEL)
86 F87 18WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN) (GAS)
86 A142 18DG/OR DIESEL POWER RELAY OUTPUT (DIESEL)
87 C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
87A --
AUTOMATIC SHUT DOWN RELAY (GAS)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
86 A0 6RD B(+)
87 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
87A --
CIGAR LIGHTER/ACCESSORY RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 Z1 18BK GROUND
86 F1 20DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
87 F30 16RD CIGAR LIGHTER/ACCESSORY RELAY OUTPUT
87A --
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CONNECTOR PINOUTS
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