relay CHRYSLER VOYAGER 2000 Diagnostic Manual

Symptom:
* CHECKING THE SECONDARY IGNITION SYSTEM
POSSIBLE CAUSES
GOOD SPARK AT SPARK PLUG #1
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
AUTO SHUTDOWN RELAY OUTPUT CIRCUIT OPEN
COIL SECONDARY CABLE DEFECTIVE
FUSED B(+) CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
IGNITION COIL CONNECTOR OBSERVABLE DEFECT
IGNITION COIL CONNECTOR OBSERVABLE DEFECT
IGNITION COIL DEFECTIVE
IGNITION COIL SECONDARY CABLE #1 DEFECTIVE
IGNITION COIL SECONDARY CABLE #4 DEFECTIVE
SECONDARY IGNITION COMPONENT(S) DEFECTIVE
SPARK PLUG CABLE #1 DEFECTIVE
AUTO SHUTDOWN RELAY DEFECTIVE
AUTO SHUTDOWN RELAY DEFECTIVE
IGNITION COIL DEFECTIVE
IGNITION COIL DEFECTIVE (RESISTANCE OUT OF RANGE)
SPARK PLUG #1 OR #4 DEFECTIVE
GOOD SPARK AT SPARK PLUG #1
GOOD SPARK AT SPARK PLUG #1
TEST ACTION APPLICABILITY
1 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #1.
Connect the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Warning: Ensure that there are no Fuel or Fuel vapors present in or near
the Engine compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 3.0L V6
Ye s®Refer to Symptom list for further diagnostic tests.
No®Go To 2
288
STARTING
ProCarManuals.com

TEST ACTION APPLICABILITY
12 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 mesaure the ASD Output Circuit for resistance to Ground at the
Relay.
Is the resistance below 5.0 ohms?ENGINE - 3.0L V6
Ye s®Go To 13
No®Repair open ASD Relay Output Circuit.
Perform Powetrain Verification Test VER-1A.
13 Ignition Off.
Disconnect the ASD Relay.
Note: Check connectors - Clean/repair as necessary.
Ignition On, Engine Not Running.
With a Voltmeter, measure the Fused B(+) Circuit cavity B in ASD Relay Connector.
Is the voltage above 10 volts?ENGINE - 3.0L V6
Ye s®Replace the Auto Shutdown Relay.
Perform Powertrain Verification Test VER-1A.
No®Repair open Fused B+.
Perform Verification TEST VER-1A
14 Ignition Off.
Remove the Distributor Cap.
Is the Distributor Rotor loose?ENGINE - 3.0L V6
Ye s®Repair loose Distributor Rotor as necessary.
Perform Verification TEST VER-1A
No®Go To 15
15 If there are no potential causes remaining, the Distributor Drive System is assumed
to be defective.
View repair options.ENGINE - 3.0L V6
Repair
Repair the Distributor Drive System.
Perform Powertrain Verification Test VER-1A.
16 Ignition Off.
Disconnect the Spark Plug Cable at Spark Plug #1.
Connect the Cable to a Spark Tester.
Connect the Spark Tester to a good Ground.
Warning: Ensure that there are no Fuel or Fuel vapors present in or near
the Engine compartment before continuing with the test.
While cranking the Engine for 10 seconds, watch for spark.
Is there good spark?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Refer to Symptom list for further diagnostic tests.
No®Go To 17
291
STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
ProCarManuals.com

TEST ACTION APPLICABILITY
21 Ignition Off.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #1.
Note: Check connectors - Clean/repair as necessary.
Disconnect the Ignition Coil Secondary Cable at Spark Plug #4.
Note: Check connectors - Clean/repair as necessary.
Note: Either Spark Plug #1 or #4 will not produce a good spark.
Remove Spark Plugs #1 and #4.
Inspect and determine which Spark Plug needs replacement.
View repair options.ENGINE - 2.0L
and 2.4L I-4 DOHC
Repair
Replace the Spark Plug that will not produce a spark.
Perform Powertrain Verification Test VER-1A.
22 Ignition Off.
Disconnect the Ignition Coil Connector.
Note: Check connectors - Clean/repair as necessary.
Inspect Terminals.
Is any Terminal damaged, pushed out, or miswired?ENGINE - 2.0L
and 2.4L I-4 DOHC
Ye s®Repair Terminal(s) for damage, pushout, or miswiring.
Perform Powertrain Verification Test VER-1A.
No®Go To 23
23 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
and 2.4L I-4 DOHC
Ye s®Replace Ignition Coil.
Perform Powertrain Verification Test VER-1A.
No®Go To 24
24 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
and 2.4L I-4 DOHC
Ye s®Go To 25
No®Repair open ASD Relay Output Circuit.
Perform Powertrain Verification Test VER-1A.
25 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
and 2.4L I-4 DOHC
Ye s®Replace the Auto Shutdown Relay.
Perform Verification Test VER-1A
No®Repair open Fused B(+).
Perform Verification TEST VER-1A
293
STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
ProCarManuals.com

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
295
STARTING
* CHECKING THE SECONDARY IGNITION SYSTEM ÐContinued
ProCarManuals.com

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.
296
STARTING
ProCarManuals.com

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.
297
STARTING
* NO CRANK CONDITION ÐContinued
ProCarManuals.com

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.
298
STARTING
* NO CRANK CONDITION ÐContinued
ProCarManuals.com

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.
299
STARTING
* NO CRANK CONDITION ÐContinued
ProCarManuals.com

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
ProCarManuals.com

9.0 CONNECTOR PINOUTS
A/C COMPRESSOR CLUTCH - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 C3 18DB/BK A/C CLUTCH COMPRESSOR RELAY OUTPUT
2 Z1 18BK GROUND
AMBIENT TEMPERATURE SENSOR - GRAY 2 WAYCAV CIRCUIT FUNCTION
1 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 20BK/LB SENSOR GROUND
AMBIENT TEMPERATURE SENSOR (SENSOR SIDE) 2 WAYCAV CIRCUIT FUNCTION
1 - AMBIENT TEMPERATURE SENSOR SIGNAL
2 - SENSOR GROUND
BRAKE LAMP SWITCH - GRAY 6 WAYCAV CIRCUIT FUNCTION
1 K29 20WT/PK BRAKE SWITCH SENSE
2 Z1 20BK GROUND
3 V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
4 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
5 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
6 F32 18PK/DB FUSED B(+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
333
CONNECTOR PINOUTS
ProCarManuals.com