heater CHRYSLER VOYAGER 2001 Service Manual

Symptom:
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C
When Monitored and Set Condition:
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C
When Monitored: When the ignition is on.
Set Condition: This DTC will set if the Rear Blower Rear Control Switch, Rear Blend
Potentiometer/5 Volt Supply/Rear Temperature Feedback Signal circuit is shorted low or
high.
POSSIBLE CAUSES
REAR BLEND POTENTIOMETER SHORTED
5 VOLT SUPPLY CIRCUIT SHORTED TO REAR TEMPERATURE RETURN CIRCUIT
5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND
REAR TEMPERATURE FEEDBACK SIGNAL CIRCUIT SHORTED TO GROUND
A/C - HEATER CONTROL MODULE
5 VOLT SUPPLY CIRCUIT SHORTED TO REAR TEMPERATURE FEEDBACK SIGNAL CIRCUIT
5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
REAR TEMPERATURE FEEDBACK SIGNAL CIRCUIT SHORTED TO VOLTAGE
REAR TEMPERATURE FEEDBACK SIGNAL CKT SHORTED TO REAR TEMPERATURE RETURN
CKT
A/C - HEATER CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Turn the ignition on.
With the DRBIIItin Input/Output Display, read the Rear Blend position status.
What is the Rear Blend position status?All
Open
Replace the Rear Blower Rear Control Switch in accordance with
the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
Full Cold
Go To 2
Full Hot
Go To 5
556
HEATING & A/C

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance between the 5 Volt Supply circuit and the Rear Temperature
Return circuit.
Is the resistance above 10K ohms?All
Ye s®Go To 3
No®Repair the 5 Volt Supply circuit for a short to the Rear Temper-
ature Return circuit.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance between ground and the 5 Volt Supply circuit.
Is the resistance above 10K ohms?All
Ye s®Go To 4
No®Repair the 5 Volt Supply circuit for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance between ground and the Rear Temperature Feedback Signal
circuit.
Is the resistance above 10K ohms?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the Rear Temperature Feedback Signal circuit for a short
to ground.
Perform BODY VERIFICATION TEST - VER 1.
5 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance between the 5 Volt Supply circuit and the Rear Temperature
Feedback Signal circuit.
Is the resistance above 10K ohms?All
Ye s®Go To 6
No®Repair the 5 Volt Supply circuit for a short to the Rear Temper-
ature Feedback Signal circuit.
Perform BODY VERIFICATION TEST - VER 1.
557
HEATING & A/C
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
6 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Turn the ignition on.
Measure the voltage between the 5 Volt Supply circuit and ground.
Is there any voltage present?All
Ye s®Repair the 5 Volt Supply circuit for a short to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 7
7 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Turn the ignition on.
Measure the voltage between the Rear Temperature Feedback Signal circuit and
ground.
Is there any voltage present?All
Ye s®Repair the Rear Temperature Feedback Signal circuit for a short
to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 8
8 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance between the Rear Temperature Feedback Signal circuit and
the Rear Temperature Return circuit.
Is the resistance above 10K ohms?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the Rear Temperature Feedback Signal circuit for a short
to the Rear Temperature Return circuit.
Perform BODY VERIFICATION TEST - VER 1.
558
HEATING & A/C
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C ÐContinued

Symptom:
TX FAILURE (ACTIVE) - MANUAL A/C
When Monitored and Set Condition:
TX FAILURE (ACTIVE) - MANUAL A/C
When Monitored: When the ignition is on.
Set Condition: This DTC will set if the A/C - Heater Control Module is unable to send a
message.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE HVAC MODULE
ADDITIONAL CODE(S) PRESENT
ATTEMPT TO COMMUNICATE WITH THE PCM/ECM, BCM, AND FCM
A/C - HEATER CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, attempt to communicate with the HVAC Module.
Was the DRBIIItable to I/D or communicate with the HVAC Module?All
Ye s®Go To 2
No®Refer to Communication for the related symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition on.
With the DRBIIIt, read HVAC DTCs.
Does the DRBIIItdisplay any additional HVAC DTCs?All
Ye s®Return to the symptom list and choose the symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 3
3 Turn the ignition on.
With the DRBIIIt, attempt to communicate with the PCM/ECM.
With the DRBIIIt, attempt to communicate with the BCM.
With the DRBIIIt, attempt to communicate with the FCM.
Was the DRBIIItable to I/D or communicate with the PCM/ECM, BCM and FCM?All
Ye s®Go To 4
No®Refer to Communication for the related symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
559
HEATING & A/C

TEST ACTION APPLICABILITY
4 Turn the ignition on.
With the DRBIIIt, erase HVAC DTCs.
Cycle the ignition switch and wait approximately 1 minute.
With the DRBIIIt, read HVAC DTC's.
Did this DTC reset?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Test Complete.
560
HEATING & A/C
TX FAILURE (ACTIVE) - MANUAL A/C ÐContinued

CABIN HEATER VERIFICATION TEST - VER 1 APPLICABILITY
1. WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A
GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE DCHA's EXHAUST WHEN OPERATING THE DCHA. FAILURE TO FOL-
LOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH.
2. WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORMING A
COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
3. NOTE: The DCHA Control will store up to three DTCs in its memory.
4. NOTE: If the DCHA Control detects a new fault in the DCHA system, one that is not
already stored in its memory, the DCHA Control will clear the oldest of the three
stored DTCs, and it will store the new fault's DTC.
5. NOTE: If the DCHA control detects a reoccurrence of a stored fault, the DCHA
control will overwrite that fault's DTC with the most recent occurrence.
6. Verify that the vehicle's battery is fully charged.
7. Verify that there is more than 1/8 of a tank of fuel in the vehicle's fuel tank. Add fuel, if
necessary.
8. Verify that all DCHA coolant hoses and fuel lines are securely fastened to their respective
components.
9. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
10. If a heater installation/cooling system service was performed, purge the coolant circuit of
air in accordance with the Service Information.
11. Turn the ignition on.
12. Set the Blend Control to the max cool position.
13. Ensure that all accessories are turned off.
14. If a fuel system service requiring fuel to drain out of the DCHA fuel line was performed,
prime the DCHA Dosing Pump in accordance with the Service Information.
15. With the DRBIIIt, record and erase all DTCs from the Diesel Cabin Heater Assist (DCHA)
Control and the Front Control Module (FCM). Cycle the ignition off then on.
16. Start the engine.
17. Allow the engine to idle.
18. Turn the A/C - Heater Control Module's Power switch on.
19. Turn the Blower switch to the high speed position.
20. CAUTION: Do not activate the Diesel Cabin Heater Test with the engine off.
Failure to follow these instructions may result in internal damage to the DCHA
Heater Module.
21. NOTE: Do not disconnect the vehicle's battery or the DCHA's main power supply
while the DCHA is in operation or in run-down mode. Failure to follow these
instructions may result in excess emissions from the DCHA during heater operation.
22. NOTE: While performing the Diesel Cabin Heater Test, inspect the coolant and
fuel connections for leakage.
23. With the DRBIIItin HVAC, Systems Tests, select Diesel Cabin Heater Test and press #1.
24. Set the Blend Control to the max heat position. Allow the Diesel Cabin Heater Test to run
for five minutes. Upon completion of the test, proceed as follows:
25. Set the Blend Control to the max cool position.
26. Press #2 on the DRBIIItkeyboard.
27. Turn the Blower switch off.
28. Turn the A/C - Heater Control Module's Power switch off.
29. Turn the ignition off, wait 5 seconds, then turn the ignition on.
30. Using the DRBIIIt, read the Cabin Heater and Active FCM DTCs.
Are any DTC's present or is the original condition still present?All
Ye s®Repair is not complete, refer to the appropriate symptom.
No®Repair is complete.
991
VERIFICATION TESTS
Verification Tests ÐContinued

8.4.8 ACTUATORS ± REAR
8.4.9 REAR A/C HEATER UNIT CONNECTOR
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1000
COMPONENT LOCATIONS
8.4 HEATING & A/C (Continued)

8.5 CABIN HEATER
8.5.1 DIESEL CABIN HEATER ASSIST (CABIN HEATER) ASSEMBLY
8.5.2 C331 CONNECTOR
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1001
COMPONENT LOCATIONS

8.5.3 C330 CONNECTOR
8.7 MEMORY SYSTEM
8.7.1 MEMORY SEAT MIRROR MEDULE/SEAT MOTORS
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1002
COMPONENT LOCATIONS
8.5 CABIN HEATER (Continued)

9.0 CONNECTOR PINOUTS
A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAYCAV CIRCUIT FUNCTION
1 Z24 18BK/OR GROUND
2 C121 20DB/DG SENSOR GROUND
3 C22 20LB/WT (3 ZONE
HVAC)REAR TEMPERATURE FEEDBACK SIGNAL
4- -
5 F850 20LB/PK (3 ZONE
HVAC)5 VOLT SUPPLY
6 C900 18LB/VT WIPER DE-ICER DRIVER
7 C32 20DB/TN RECIRCULATION DOOR DRIVER (A)
8 C54 20LB/YL (3 ZONE
HVAC)REAR BLEND DOOR DRIVER
9 C34 20DB/LB COMMON DOOR DRIVER (B)
10 D25 20WT/VT PCI BUS
11 - -
12 C121 20DB/DG (3 ZONE
HVAC)REAR TEMPERATURE RETURN
13 F504 20GY/PK IGNITION SWITCH OUTPUT (RUN)
14 E12 20OR/GY PANEL LAMPS DRIVER
15 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
16 C33 20LB/BR PASSENGER BLEND DOOR DRIVER (A)
17 C61 20DB/LG DRIVER BLEND DOOR DRIVER (A)
18 C35 20LB/OR MODE DOOR DRIVER (A)
19 C53 20LB (3 ZONE HVAC) REAR MODE DOOR DRIVER
20 C154 20LB/OR (3 ZONE
HVAC)REAR COMMON DOOR DRIVER
A/C-HEATER CONTROL C2 (MTC) - BLACK/BLUE 10 WAYCAV CIRCUIT FUNCTION
1- -
2 C75 12DB/GY BLOWER MOTOR HIGH DRIVER
3 C74 12DB/WT BLOWER MOTOR M3 DRIVER
4 Z134 12BK/OR GROUND
5 C71 16DB/BR BLOWER MOTOR LOW DRIVER
6- -
7- -
8- -
9 C73 14DB/VT BLOWER MOTOR M2 DRIVER
10 C72 16DB/OR BLOWER MOTOR M1 DRIVER
AMBIENT TEMP SENSOR (EXCEPT BASE) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G931 18VT/BR AMBIENT TEMPERATURE SENSOR RETURN
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1011
CONNECTOR PINOUTS