Door CHRYSLER VOYAGER 2001 Service Manual

POSSIBLE CAUSES
CHECK FOR ACTIVE HVAC DTCS, & COOLDOWN TEST & DOOR RECALIBRATION MESSAGES
STORED CODE(S) TEST COMPLETE
TEST ACTION APPLICABILITY
1NOTE: Active codes must be resolved before diagnosing stored codes.
NOTE: Anytime a code becomes active during this test, proceed to the
conclusion question.
Turn the ignition on.
With the DRBIIIt, record and erase stored HVAC DTC's.
Cycle the ignition switch.
Start the engine.
Monitor the DRBIIItfor active HVAC DTCs while performing the following test
steps.
Manually press the A/C - Heater Control power switch on.
Turn the front blower motor control switch knob to the low position.
If equipped, turn the rear blower motor control switch knob to the low position.
Set the passenger blend control switch to the full cold position.
If equipped, set the zone/driver blend control switch to the full cold position.
Turn the mode select switch knob to the panel position.
Manually press the recirculation mode switch on, wait 30 seconds then press it off.
Manually press the A/C mode switch on, wait 30 seconds then press it off.
Manually press the rear window defogger switch on, wait 30 seconds then press it off.
Manually sweep the passenger blend control switch from full cold to full hot then
back to full cold.
If equipped, manually sweep the zone/driver blend control switch from full cold to full
hot then back to full cold.
Manually sweep the front blower motor control switch knob through all positions.
If equipped, manually sweep the rear blower motor control switch knob through all
positions.
If equipped, turn the rear blower motor control switch knob to the rear position.
If equipped, on the Rear Blower Rear Control, manually sweep the rear blower motor
control switch knob through all positions.
If equipped, on the Rear Blower Rear Control, manually sweep the rear blend/mode
control switch knob from full cold to full hot then back to full cold.
With the DRBIIIt, actuate the AC Cooldown Test.
With the DRBIIIt, actuate the HVAC Door Recalibration Test.
Place the vehicle on a hoist, and raise the wheels off the floor.
WARNING: Be sure to keep hands and feet clear of rotating wheels. Keep
clear of the engine's moving parts
Start the engine. Place the transmission in drive. Brake off.
Does the DRBIIItdisplay any active HVAC DTC(s), Cooldown Test or Door Recali-
bration message(s)?All
Ye s®Return to the symptom list and choose the symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
No®No problem found at this time.
Perform BODY VERIFICATION TEST - VER 1.
518
HEATING & A/C
A/C FAULT (STORED) - MANUAL A/C ÐContinued

Symptom List:
BLEND CALIBRATION FAULT - MANUAL A/C
MODE CALIBRATION FAULT - MANUAL A/C
RECIRCULATION CALIBRATION FAULT - MANUAL A/C
ZONE CALIBRATION FAULT - MANUAL A/C
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be BLEND CALIBRATION FAULT -
MANUAL A/C.
When Monitored and Set Condition:
BLEND CALIBRATION FAULT - MANUAL A/C
When Monitored: When the HVAC Door Recalibration is executed. With the ignition on
(door actuator(s)/circuit(s) shorted low only).
Set Condition: If the Blend Door (Pass) drive span found is outside the tolerance. If the
Blend Door Actuator (Pass)/circuit is open. If the Blend Door(s) (Driver [Zone], Pass, Rear),
Mode Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s) are shorted low. (This
will also set Blend Calibration/Overcurrent (Front, Rear), Mode Calibration/Overcurrent
(Front, Rear), Recirculation Calibration/Overcurrent, Zone Calibration/Overcurrent
DTCs.)
MODE CALIBRATION FAULT - MANUAL A/C
When Monitored: When the HVAC Door Recalibration is executed. With the ignition on
(door actuator(s)/circuit(s) shorted low only).
Set Condition: If the Mode Door drive span found is outside the tolerance. If the Mode
Door Actuator/circuit is open. If the Blend Door(s) (Driver [Zone], Pass, Rear), Mode
Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s) are shorted low. (This will
also set Blend Calibration/Overcurrent (Front, Rear), Mode Calibration/Overcurrent
(Front, Rear), Recirculation Calibration/Overcurrent, Zone Calibration/Overcurrent
DTCs.)
RECIRCULATION CALIBRATION FAULT - MANUAL A/C
When Monitored: When the HVAC Door Recalibration is executed. With the ignition on
(door actuator(s)/circuit(s) shorted low only).
Set Condition: If the Recirculation Door drive span found is outside the tolerance. If the
Recirculation Door Actuator/circuit is open. If the Blend Door(s) (Driver [Zone], Pass,
Rear), Mode Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s) are shorted
low. (This will also set Blend Calibration/Overcurrent (Front, Rear), Mode Calibration/
Overcurrent (Front, Rear), Recirculation Calibration/Overcurrent, Zone Calibration/
Overcurrent DTCs.)
521
HEATING & A/C

ZONE CALIBRATION FAULT - MANUAL A/C
When Monitored: When the HVAC Door Recalibration is executed. With the ignition on
(door actuator(s)/circuit(s) shorted low only).
Set Condition: If the Blend Door (Driver [Zone]) drive span found is outside the tolerance.
If the Blend Door Actuator (Driver [Zone])/circuit is open. If the Blend Door(s) (Driver
[Zone], Pass, Rear), Mode Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s)
are shorted low. (This will also set Blend Calibration/Overcurrent (Front, Rear), Mode
Calibration/Overcurrent (Front, Rear), Recirculation Calibration/Overcurrent, Zone
Calibration/Overcurrent DTCs.)
POSSIBLE CAUSES
HVAC DTC(S) PRESENT
DOOR ACTUATOR
BLEND ACTUATOR/LINKAGE/DOOR
RECIRCULATION ACTUATOR/LINKAGE/DOOR
MODE ACTUATOR/LINKAGE/DOOR
DOOR ACTUATOR DRIVER CIRCUIT OPEN
COMMON DOOR DRIVER CIRCUIT OPEN
A/C - HEATER CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: All Overcurrent DTCs must be repaired before diagnosing Calibra-
tion messages.
Turn the ignition on.
With the DRBIIIt, read HVAC DTCs.
Does the DRBIIItdisplay any HVAC DTCs?All
Ye s®Return to the symptom list and choose the symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 2
522
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Remove the applicable door actuator (Blend [Driver (Zone), Passenger], Recircula-
tion, Mode) from the A/C - Heater Housing Assembly.
Disconnect the door actuator harness connector.
By hand, attempt to rotate the door actuator in both directions.
Did the door actuator turn in either direction?All
Ye s®Replace the door actuator in accordance with the Service Infor-
mation.
Perform BODY VERIFICATION TEST - VER 1.
No: Blend Actuator (Driver [Zone], Pass)
Go To 3
No: Recirculation Door Actuator
Go To 4
No: Mode Door Actuator
Go To 5
3 Turn the ignition off.
Remove the applicable blend door actuator (Driver [Zone], Passenger) from the A/C
- Heater Housing Assembly.
Disconnect the blend door actuator harness connector.
Set the applicable blend control switch knob (Driver [Zone], Passenger) to the full
cold position.
Connect a 12-volt Test Light across the blend door actuator harness connector.
Turn the ignition on.
While monitoring the test light, manually sweep the applicable blend control switch
knob (Driver [Zone], Passenger) very slowly from full cold to full hot.
While monitoring the test light, manually sweep the applicable blend control switch
knob (Driver [Zone], Passenger) very slowly from full hot to full cold.
Does the test light start to flash and stay flashing through the entire range?All
Ye s®Inspect A/C - Heater Housing for missing & broken actuator
linkage. Inspect linkage & actuator for broken & missing teeth.
Check doors for binding & loss of full range. Repair as necessary.
If Ok, replace the actuator in accordance with the Service Info.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 6
523
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
4 Turn the mode door knob to the Panel, Bi-level, or Floor position.
Turn the ignition off.
Remove the Recirculation Door Actuator from the A/C - Heater Housing Assembly.
Disconnect the Recirculation Door Actuator harness connector.
Connect a 12-volt Test Light across the Recirculation Door Actuator harness
connector.
Turn the ignition on.
If the LED on the recirculation mode switch is illuminated, manually press the
recirculation mode switch to turn the recirculation mode off.
While monitoring the test light, manually press the recirculation mode switch on
(LED on).
While monitoring the test light, manually press the recirculation mode switch off
(LED off).
Does the test light flash 4 times after pressing the switch on and 2 times after
pressing it off?All
Ye s®Inspect the linkage and the actuator for broken and missing
teeth. Check the door for binding and loss of full range. Repair as
necessary. If Ok, replace the door actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 6
5 Turn the ignition off.
Remove the Mode Door Actuator from the A/C - Heater Housing Assembly.
Disconnect the Mode Door Actuator harness connector.
Turn the mode select switch knob to the panel position, then to the defrost position,
then back to the panel position.
Connect a 12-volt Test Light across the Mode Door Actuator harness connector.
Turn the ignition on.
While monitoring the test light, turn the mode select switch knob to the first detent
after the panel position.
Repeat the previous step for each detent, until reaching the defrost mode position.
Does the test light flash four times after turning the mode select switch knob to each
detent?All
Ye s®Inspect A/C - Heater Housing for missing & broken actuator
linkage. Inspect linkage & actuator for broken & missing teeth.
Check doors for binding & loss of full range. Repair as necessary.
If Ok, replace the actuator in accordance with the Service Info.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 6
6 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Remove the applicable door actuator (Blend [Driver (Zone), Passenger], Recircula-
tion, Mode) from the A/C - Heater Housing Assembly.
Disconnect the door actuator harness connector.
Measure the resistance of the applicable door driver circuit (Blend [Driver (Zone),
Passenger], Recirculation, Mode) between the A/C - Heater Control Module C1
harness connector and the door actuator harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the applicable door driver circuit (Blend [Driver (Zone),
Passenger], Recirculation, Mode) for an open.
Perform BODY VERIFICATION TEST - VER 1.
524
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Remove the applicable door actuator (Blend [Driver (Zone), Passenger], Recircula-
tion, Mode) from the A/C - Heater Housing Assembly.
Disconnect the door actuator harness connector.
Measure the resistance of the Common Door Driver circuit between the applicable
door actuator harness connector (Blend [Driver (Zone), Passenger], Recirculation,
Mode) and the A/C - Heater Control Module C1 harness connector.
Is the resistance below 5.0 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 Common Door Driver circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
525
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

Symptom List:
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
MODE OVERCURRENT (ACTIVE) - MANUAL A/C
REAR BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
REAR MODE OVERCURRENT (ACTIVE) - MANUAL A/C
RECIRC OVERCURRENT (ACTIVE) - MANUAL A/C
ZONE OVERCURRENT (ACTIVE) - MANUAL A/C
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be BLEND OVERCURRENT (AC-
TIVE) - MANUAL A/C.
When Monitored and Set Condition:
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
MODE OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
REAR BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
REAR MODE OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
RECIRC OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
526
HEATING & A/C

ZONE OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
POSSIBLE CAUSES
MODE DOOR ACTUATOR SHORTED
RECIRCULATION DOOR ACTUATOR SHORTED
PASSENGER BLEND DOOR ACTUATOR SHORTED
DRIVER BLEND DOOR ACTUATOR SHORTED
DOOR DRIVER CIRCUIT SHORTED TO GROUND
DOOR DRIVER CIRCUITS SHORTED TOGETHER
A/C - HEATER CONTROL MODULE
REAR BLEND DOOR ACTUATOR SHORTED
REAR MODE DOOR ACTUATOR SHORTED
REAR A/C HEATER UNIT WIRING HARNESS SHORTED
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Mode Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time.
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 2
No®Replace the Mode Door Actuator in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
527
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Disconnect the Recirculation Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 3
No®Replace the Recirculation Door Actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the Passenger Blend Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 4
No®Replace the Passenger Blend Door Actuator in accordance with
the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
528
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
4NOTE: If vehicle is equipped with a base HVAC system, answer yes to the
question.
Turn the ignition off.
Disconnect the Driver (zone) Blend Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 5
No®Replace the Driver Blend Door Actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
5NOTE: If vehicle is equipped with a base HVAC or dual zone system, answer
yes to the question.
Turn the ignition off.
Disconnect the Rear A/C Heater Unit harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot. Perform
this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 6
No®Go To 8
6 Turn the ignition off.
Disconnect each door actuator harness connector (front actuators only).
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear A/C Heater Unit harness connector (if equipped with rear A/C).
Measure the resistance between ground and each HVAC door driver circuit.
Is the resistance below 10K ohms for any of the measurements?All
Ye s®Repair all door driver circuits with a resistance below 10K ohms
for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 7
529
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued