wiring CHRYSLER VOYAGER 2001 Owners Manual

Symptom:
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (ACTIVE)
- MANUAL A/C
When Monitored and Set Condition:
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (ACTIVE) - MANUAL
A/C
When Monitored: With the ignition on.
Set Condition: This DTC will set if the Evaporator Temperature Sensor/sensor circuit is
open.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE SENSOR
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
SENSOR GROUND CIRCUIT OPEN
A/C - HEATER CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Open the glove box door. Disconnect the glove box door roller latch from each side of
the glove box. Roll the glove box downward toward the floor.
Disconnect the in-line C202 harness connector.
Connect a jumper wire between the Evaporator Temperature Sensor Signal circuit
and the Sensor Ground circuit at the in-line C202 harness connector (HVAC side).
Turn the ignition on.
With the DRBIIItin Sensor Display, read the Evaporator Temperature Sensor
voltage.
Does the DRBIIItdisplay: 0.0 volts?All
Ye s®Check the wiring harness between the in-line C202 harness
connector (plenum side) and the Evap Temp Sensor for an open.
Repair as necessary. If Ok, replace the Evaporator Temperature
Sensor in accordance with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 2
538
HEATING & A/C

Symptom List:
FRONT AND REAR BLOWER OUTPUT 1 OPEN
FRONT AND REAR BLOWER OUTPUT 2 OPEN
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be FRONT AND REAR BLOWER
OUTPUT 1 OPEN.
When Monitored and Set Condition:
FRONT AND REAR BLOWER OUTPUT 1 OPEN
When Monitored: Continuously.
Set Condition: If the FCM detects no voltage present on the Front/Rear Blower Motor
Relay Control circuit.
FRONT AND REAR BLOWER OUTPUT 2 OPEN
When Monitored: Continuously.
Set Condition: If the FCM detects no voltage present on the Front/Rear Blower Motor
Relay Control circuit.
POSSIBLE CAUSES
CHECK DTCS
B+ CIRCUIT OPEN
FRONT AND REAR BLOWER RELAYS OPEN
FRONT/REAR BLOWER MOTOR RELAY CONTROL CIRCUIT SHORTED TO GROUND
FRONT/REAR BLOWER MOTOR RELAY CONTROL CIRCUIT OPEN
FRONT CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
NOTE: If neither DTC will reset or is active, refer to the wiring diagrams
located in the service information to help isolate a possible intermittent
condition.
With the DRB, read the FCM DTC's.
Are both the Front/Rear Blower Output 1 Open and the Front/Rear Blower Output
2 Open DTC's set?All
Ye s®Go To 2
No®Replace the Front Control Module (FCM) in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
542
HEATING & A/C

Symptom List:
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT
FRONT AND REAR BLOWER OUTPUT 2 SHORT TO BATT
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be FRONT AND REAR BLOWER
OUTPUT 1 SHORT TO BATT.
When Monitored and Set Condition:
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT
When Monitored: With the ignition on.
Set Condition: The FCM detects excessive current when attempting to close the Front/
Rear Blower Motor Relays.
FRONT AND REAR BLOWER OUTPUT 2 SHORT TO BATT
When Monitored: With the ignition on.
Set Condition: The FCM detects excessive current when attempting to close the Front/
Rear Blower Motor Relays.
POSSIBLE CAUSES
CHECK DTCS
FRONT BLOWER MOTOR RELAY SHORTED
REAR BLOWER MOTOR RELAY SHORTED
FRONT/REAR BLOWER MOTOR RELAY CONTROL CIRCUIT SHORTED TO BATTERY
FRONT CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
NOTE: If neither DTC will reset or is active, refer to the wiring diagrams
located in the service information to help isolate a possible intermittent
condition.
With the DRB, read the FCM DTC's.
Are both of these DTCs set?All
Ye s®Go To 2
No®Replace the Front Control Module (FCM) in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
544
HEATING & A/C

Symptom:
FRONT FOG LAMP INDICATOR OPEN
POSSIBLE CAUSES
INTERMITTENT WIRING AND CONNECTORS
FRONT FOG LAMP INDICATOR CIRCUIT OPEN
FRONT FOG LAMP INDICATOR GROUND CIRCUIT OPEN
FRONT FOG LAMP INDICATOR CIRCUIT SHORT TO VOLTAGE
HEADLAMP SWITCH
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, record and erase Body Control Module DTC's.
Turn the ignition off, wait 15 seconds, then turn the ignition on.
Turn on the Front Fog Lamps.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay FRONT FOG LAMP INDICATOR OPEN?All
Ye s®Go To 2
No®Go To 8
2 Turn the ignition off to the lock position.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Turn ON the Front Fog Lamps.
Using a 12-volt test light connected to ground, back probe the Front Fog Lamp
Indicator circuit in the Headlamp Switch harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Go To 6
3 Turn the ignition off to the lock position.
Disconnect the Body Control Module harness connector.
Disconnect the Headlamp Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Front Fog Lamp Indicator Ground circuit from the
Body Control Module harness connector to the Headlamp Switch harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Front Fog Lamp Indicator Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 4
567
INSTRUMENT CLUSTER

TEST ACTION APPLICABILITY
4 Turn the ignition off to the lock position.
Disconnect the Body Control Module harness connector.
Disconnect the Headlamp Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Measure the voltage of the Front Fog Lamp Indicator circuit in the Headlamp Switch
harness connector.
Is the voltage above 0.5 volt?All
Ye s®Repair the Front Fog Lamp Indicator circuit for a short to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 5
5 If there are no possible causes remaining, view repair. All
Repair
Replace the Headlamp Switch.
Perform BODY VERIFICATION TEST - VER 1.
6 Turn the ignition off to the lock position.
Disconnect the Body Control Module harness connector.
Disconnect the Headlamp Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Front Fog Lamp Indicator circuit from the Body
Control Module harness connector to the Headlamp Switch harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Front Fog Lamp Indicator circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 7
7 If there are no possible causes remaining, view repair. All
Repair
Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
8 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?All
Ye s®Repair as necessary.
Perform BODY VERIFICATION TEST - VER 1.
No®Test Complete.
568
INSTRUMENT CLUSTER
FRONT FOG LAMP INDICATOR OPEN ÐContinued

Symptom:
FRONT FOG LAMP INDICATOR SHORT TO GROUND
POSSIBLE CAUSES
INTERMITTENT WIRING AND CONNECTORS
FRONT FOG LAMP INDICATOR CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, record and erase Body Control Module DTC's.
Turn the ignition off, wait 15 seconds, then turn the ignition on.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay FRONT FOG LAMP INDICATOR SHORT TO GROUND?All
Ye s®Go To 2
No®Go To 6
2 Turn the ignition off to the lock position.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Turn ON the Front Fog Lamps.
Using a 12-volt test light connected to ground, back probe the Rear Fog Lamp
Indicator circuit in the Headlamp Switch harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Go To 4
3 If there are no possible causes remaining, view repair. All
Repair
Replace the Headlamp Switch.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off to the lock position.
Disconnect the Body Control Module harness connector.
Disconnect the Headlamp Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the Front Fog Lamp Indicator circuit.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Front Fog Lamp Indicator circuit for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 5
5 If there are no possible causes remaining, view repair. All
Repair
Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
569
INSTRUMENT CLUSTER

TEST ACTION APPLICABILITY
6 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?All
Ye s®Repair as necessary.
Perform BODY VERIFICATION TEST - VER 1.
No®Test Complete.
570
INSTRUMENT CLUSTER
FRONT FOG LAMP INDICATOR SHORT TO GROUND ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition on.
Disconnect the Fuel Tank Module harness connector.
Measure the resistance of the Ground circuits in the Fuel Tank Module harness
connector.
Is the resistance below 5.0 ohms for both measurements?All
Ye s®Go To 4
No®Repair the Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the Fuel Tank Module harness connector.
Turn the ignition on.
With the DRBIIItin Body Computer then Sensors, monitor the Fuel Sensor.
Using a jumper wire, jumper the Fuel Level Sensor Signal circuit to the ground
circuit in the Fuel Tank Module harness connector.
Does the DRB display below 0.5 volt?All
Ye s®Replace the Fuel Level Sending Unit.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 5
5 Turn the ignition off.
Disconnect the Fuel Tank Module harness connector.
Disconnect the BCM C3 harness connector.
Measure the resistance of the Fuel Level Sensor Signal circuit between the Fuel Tank
Module harness connector and the BCM harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Fuel Level Sensor Signal for an open.
Perform BODY VERIFICATION TEST - VER 1.
6 If there are no possible causes remaining, view repair. All
Repair
Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
7WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
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.
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 BODY VERIFICATION TEST - VER 1.
No®Test Complete.
573
INSTRUMENT CLUSTER
FUEL LEVEL SENDING UNIT INPUT OPEN ÐContinued

TEST ACTION APPLICABILITY
4 If there are no possible causes remaining, view repair. All
Repair
Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
5WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
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.
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 BODY VERIFICATION TEST - VER 1.
No®Test Complete.
575
INSTRUMENT CLUSTER
FUEL LEVEL SENDING UNIT INPUT SHORT ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the Instrument Cluster harness connector.
Disconnect the BCM C4 harness connector.
Measure the resistance of the Instrument Cluster Wake Up Sense circuit between the
BCM C4 harness connector and the MIC harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the Instrument Cluster Wake Up Sense circuit for an
open.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the Instrument Cluster harness connector.
Disconnect the BCM C4 harness connector.
Measure the resistance of the Instrument Cluster Wake Up Sense circuit in the MIC
harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Instrument Cluster Wake Up Sense circuit for a
shorted to ground.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the Instrument Cluster.
Perform BODY VERIFICATION TEST - VER 1.
5WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
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.
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 BODY VERIFICATION TEST - VER 1.
No®Test Complete.
577
INSTRUMENT CLUSTER
IOD WAKEUP CLUSTER OUTPUT OPEN ÐContinued