engine CHRYSLER VOYAGER 2001 Service Manual

ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAYCAV CIRCUIT FUNCTION
82 - -
83 - -
84 - -
85 - -
86 T753 20DG/YL IGNITION SWITCH OUTPUT (START)
87 - -
88 K35 20GY/YL EGR SOLENOID CONTROL
89 K35 20GY/YL EGR SOLENOID CONTROL
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
101 - -
102 - -
103 - -
104 - -
105 - -
106 - -
107 - -
108 - -
109 - -
110 - -
111 - -
112 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE
113 - -
114 - -
115 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL
116 K111 14DB/LB COMMON INJECTOR DRIVER
117 - -
118 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL
119 K12 14TN FUEL INJECTOR NO. 2 CONTROL
120 K13 14BR/LB FUEL INJECTOR NO. 3 CONTROL
121 - -
EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 C121 20DB/DG SENSOR GROUND
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CONNECTOR PINOUTS

INTELLIGENT POWER MODULE C2 - GREEN/BLUE 10 WAYCAV CIRCUIT FUNCTION
1 N173 18DB/VT (EXCEPT
BUILT-UP-EXPORT/GAS)RADIATOR FAN RELAY CONTROL
1 N173 16DB/VT (BUILT-UP-
EXPORT/GAS)RADIATOR FAN RELAY CONTROL
2 V53 12BR/OR (BUILT-UP-
EXPORT)HEADLAMP WASHER RELAY OUTPUT
3 L60 18WT/TN (EXCEPT
BUILT-UP-EXPORT)RIGHT FRONT TURN SIGNAL DRIVER
3 L60 16WT/TN (BUILT-UP-
EXPORT)RIGHT FRONT TURN SIGNAL DRIVER
4 L13 18WT/YL (BUILT-UP-
EXPORT)HEADLAMP ADJUST SIGNAL
5 X2 18DG/OR HORN RELAY OUTPUT
6 L90 18WT/OR (FOG
LAMPS)FRONT FOG LAMP RELAY OUTPUT
7 L61 18WT/LG (EXCEPT
BUILT-UP-EXPORT)LEFT FRONT TURN SIGNAL DRIVER
7 L61 16WT/LG (BUILT-UP-
EXPORT)LEFT FRONT TURN SIGNAL DRIVER
8- -
9 A112 12OR/RD FUSED B(+)
10 L89 18WT/YL (FOG
LAMPS)FRONT FOG LAMP RELAY OUTPUT
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAYCAV CIRCUIT FUNCTION
1 N21 20DB/TN LIFT PUMP RELAY CONTROL
2- -
3 T751 20YL IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT TRS REVERSE SENSE
5 N2 18DB/YL LIFT PUMP RELAY OUTPUT
6 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
8 Z114 18BK/LG GROUND
9 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A119 16RD/OR FUSED B(+)
11 C41 20LB/DG CABIN HEATER ASSIST CONTROL
12 T753 20DG/YL IGNITION SWITCH OUTPUT (START)
13 - -
14 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 20BR/WT ECM/PCM RELAY CONTROL
17 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
18 - -
19 K342 16BR/WT ECM/PCM RELAY OUTPUT
20 - -
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CONNECTOR PINOUTS

INTELLIGENT POWER MODULE C3 (GAS) - NATURAL/RED 20 WAYCAV CIRCUIT FUNCTION
1 Z115 20BK/OR (EATX)
(3.3L/3.8L)GROUND
1 Z115 18BK/OR (EATX)
(2.4L)GROUND
2 F1 18PK/WT (EATX) FCM OUTPUT (UNLOCK-RUN-START)
3 T751 18YL (EATX) IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT TRS REVERSE SENSE
5 T16 18YL/OR (EATX) TRANSMISSION CONTROL RELAY OUTPUT
6 T15 18YL/BR (EATX) TRANSMISSION CONTROL RELAY CONTROL
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
8 K31 18BR FUEL PUMP RELAY CONTROL
9 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A104 18YL/RD (EATX) FUSED B(+)
11 - -
12 - -
13 D25 18WT/VT (EATX) PCI BUS (EATX)
14 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 18BR/WT AUTOMATIC SHUTDOWN RELAY CONTROL
17 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
18 K173 18BR/VT RADIATOR FAN RELAY CONTROL
19 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
20 A109 18OR/RD FUSED B(+)
INTELLIGENT POWER MODULE C4 - BLUE 10 WAYCAV CIRCUIT FUNCTION
1 Z127 12BK/DG (GAS) GROUND
2 T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT
3 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
3 K342 16BR/WT (GAS) AUTOMATIC SHUTDOWN RELAY OUTPUT
4 F500 16DG/PK (EXCEPT
MTX))FUSED IGNITION SWITCH OUTPUT (RUN)
5- -
6 D25 16WT/VT (ANTILOCK
BRAKES)PCI BUS
7 A107 12TN/RD (ANTILOCK
BRAKES)FUSED B(+)
8 A111 12DG/RD (ANTILOCK
BRAKES)FUSED B(+)
9 A701 14BR/RD (GAS) B(+) (HAZARD FEED)
9 A710 14BR/RD (DIESEL) B(+) (HAZARD FEED)
10 - -
INTELLIGENT POWER MODULE C5 - BLACK 4 WAYCAV CIRCUIT FUNCTION
1 A1 4RD B(+)
2- -
3- -
4- -
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CONNECTOR PINOUTS

POWERTRAIN CONTROL MODULE C1 (2.4L/3.3L/3.8L) - GRAY/BLACK 40-WAYCAV CIRCUIT FUNCTION
1- -
2 K18 16DB/OR (3.3L/3.8L) IGNITION COIL NO. 3 DRIVER
3 K17 16DB/TN IGNITION COIL NO. 2 DRIVER
4- -
5 V32 18VT/YL SPEED CONTROL ON/OFF SWITCH SENSE
6 K342 16BR/WT AUTOMATIC SHUTDOWN RELAY OUTPUT
7 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER
8 K20 18BR/GY GENERATOR FIELD CONTROL
9- -
10 Z130 18BK/BR GROUND
11 K19 16DB/DG IGNITION COIL NO. 1 DRIVER
12 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
13 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER
14 K58 16BR/VT (3.3L/3.8L) FUEL INJECTOR NO. 6 DRIVER
15 K38 16BR/OR (3.3L/3.8L) FUEL INJECTOR NO. 5 DRIVER
16 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER
17 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER
18 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL
19 - -
20 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
21 - -
22 - -
23 - -
24 - -
25 K42 18DB/YL KNOCK SENSOR SIGNAL
26 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
27 K902 18BR/DG OXYGEN SENSOR GROUND
28 - -
29 - -
30 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL
31 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
32 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL
34 - -
35 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
36 K1 18VT/BR MANIFOLD ABOLUTE PRESSURE SENSOR SIGNAL
37 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
38 - -
39 - -
40 K35 18DB/VT EGR SOLENOID CONTROL
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CONNECTOR PINOUTS

4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive
vehicles; the parking brake does not hold the drive
wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
rings, watchbands or bracelets that might make an
inadvertent electrical contact.
When diagnosing a chassis problem, it is impor-
tant to follow approved procedures where applica-
ble. These procedures can be found in the service
manual. Following these procedures is very impor-
tant to the safety of individuals performing diag-
nostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If is does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the chassis system are in-
tended to be serviced as an assembly only. Attempt-
ing to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRB MULTIMETER IS DANGEROUS. IT CAN
EXPOSE YOU TO SERIOUS OR POSSIBLY
FATAL INJURY. CAREFULLY READ AND
UNDERSTAND THE CAUTIONS AND THE
SPECIFICATION LIMITS.
²Follow the vehicle manufacturer 's service speci-
fications at all times.
²Do not use the DRBIIItif it has been damaged.
²Do not use the test leads if the insulation is
damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test
leads, tips, or the circuit being tested.
²Choose the proper range and functions for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
²Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 -1.12 megohms
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100ÉF
-50 - 600ÉC
* Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
²Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
²Use caution when measuring voltage above 25v
DC or 25v AC.
²Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeding 10A.
²When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before accepting a zero reading.
²When measuring current, connect the meter in
series with the load.
²Disconnect the live test lead before disconnecting
the common test lead.
²When using the meter function, keep the
DRBIIItaway from spark plug or coil wires to
avoid measuring error from outside interference.
5
GENERAL INFORMATION

Symptom:
LEFT FRONT WHEEL SPEED SIGNAL FAILURE
When Monitored and Set Condition:
LEFT FRONT WHEEL SPEED SIGNAL FAILURE
When Monitored: Wheel speed comparison is checked at drive off or every 7 milliseconds
(ms). Sensor signal continuity is checked every 7 milliseconds. Wheel speed phase length
supervision is checked every 7 milliseconds.
Set Condition: If, during an ABS stop, the CAB commands any valve solenoid on for an
extended length of time, and does not see a corresponding wheel speed change, the
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
POSSIBLE CAUSES
SENSOR OR TONE WHEEL CONCERN
DTC INTERMITTENT
LEFT FRONT WHEEL SPEED SENSOR INOPERATIVE
INTERMITTENT SIGNAL DTC
TEST ACTION APPLICABILITY
1 With the DRBIIIt, erase DTCs.
Turn the ignition off.
Start the engine.
Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph).
Using the DRBIIIt, monitor the Left Front Wheel Speed Sensor while an assistant
drives the vehicle.
With the DRBIIIt, monitor all wheel speed sensors.
Is Left Front WSS Signal 0 km/h (0 mph) or differing from others by more than 5
km/h (3 mph)?All
Ye s®Go To 2
No®Go To 3
2 Inspect the Left Front Wheel Speed Sensor, Connector and Tone Wheel.
NOTE: Inspect components for damage and correct installation.
Are there any visible Sensor, Connector or Tone Wheel concerns?All
Ye s®Correct the sensor, connector or tone wheel concern as necessary.
The vehicle must be driven at 25 km/h (15 mph) to extinguish the
ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
No®Replace the Left Front Wheel Speed Sensor in accordance with
the Service Information. The vehicle must be driven at 25 km/h
(15 mph) to extinguish the ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)

Symptom:
LEFT REAR WHEEL SPEED SIGNAL FAILURE
When Monitored and Set Condition:
LEFT REAR WHEEL SPEED SIGNAL FAILURE
When Monitored: Wheel speed comparison is checked at drive off or every 7 milliseconds
(ms). Wheel speed circuit continuity is checked every 7 milliseconds. Wheel speed phase
length supervision is checked every 7 milliseconds.
Set Condition: If, during an ABS stop, the CAB commands any valve solenoid on for an
extended length of time, and does not see a corresponding wheel speed change, the
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
POSSIBLE CAUSES
SENSOR OR TONE WHEEL CONCERN
DTC INTERMITTENT
LEFT REAR WHEEL SPEED SENSOR INOPERATIVE
INTERMITTENT SIGNAL DTC
TEST ACTION APPLICABILITY
1 With the DRBIIIt, erase DTCs.
Turn the ignition off.
Start the engine.
Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph).
Using the DRBIIIt, monitor the Left Rear Wheel Speed Sensor while an assistant
drives the vehicle.
With the DRBIIIt, monitor all wheel speed sensors.
Is Left Rear WSS Signal 0 km/h (0 mph) or differing from others by more than 5 km/h
(3 mph)?All
Ye s®Go To 2
No®Go To 3
2 Inspect the Left Rear Wheel Speed Sensor, Connector and Tone Wheel.
NOTE: Inspect components for damage and correct installation.
Are there any visible Sensor, Connector or Tone Wheel concerns?All
Ye s®Correct the sensor, connector or tone wheel concern as necessary.
The vehicle must be driven at 25 km/h (15 mph) to extinguish the
ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
No®Replace the Left Rear Wheel Speed Sensor in accordance with the
Service Information. The vehicle must be driven at 25 km/h (15
mph) to extinguish the ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)

Symptom:
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE
When Monitored and Set Condition:
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE
When Monitored: Wheel speed comparison is checked at drive off or every 7 milliseconds
(ms). Wheel speed continuity is checked every 7 milliseconds. Wheel speed phase length
supervision is checked every 7 milliseconds.
Set Condition: If, during an ABS stop, the CAB commands any valve solenoid on for an
extended length of time, and does not see a corresponding wheel speed change, the
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
POSSIBLE CAUSES
SENSOR OR TONE WHEEL CONCERN
DTC INTERMITTENT
RIGHT FRONT WHEEL SPEED SENSOR INOPERATIVE
CAB - WON'T RESPOND TO RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
INTERMITTENT SIGNAL DTC
TEST ACTION APPLICABILITY
1 With the DRBIIIt, erase DTCs.
Turn the ignition off.
Start the engine.
Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph).
Using the DRBIIIt, monitor the Right Front Wheel Speed Sensor while an assistant
drives the vehicle.
With the DRBIIIt, monitor all wheel speed sensors.
Is Right Front WSS Signal 0 km/h (0 mph) or differing from others by more than 5
km/h (3 mph)?All
Ye s®Go To 2
No®Go To 3
2 Inspect the Right Front Wheel Speed Sensor, Connector and Tone Wheel.
NOTE: Inspect components for damage and correct installation.
Are there any visible Sensor, Connector or Tone Wheel concerns?All
Ye s®Correct the sensor, connector or tone wheel concern as necessary.
The vehicle must be driven at 25 km/h (15 mph) to extinguish the
ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
No®Replace the Right Front Wheel Speed Sensor in accordance with
the Service Information. The vehicle must be driven at 25 km/h
(15 mph) to extinguish the ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)

Symptom:
RIGHT REAR WHEEL SPEED SIGNAL FAILURE
When Monitored and Set Condition:
RIGHT REAR WHEEL SPEED SIGNAL FAILURE
When Monitored: Wheel speed comparison is checked at drive off or every 7 milliseconds
(ms). Wheel speed circuit continuity is checked every 7 milliseconds. Wheel speed phase
length supervision is checked every 7 milliseconds.
Set Condition: If, during an ABS stop, the CAB commands any valve solenoid on for an
extended length of time, and does not see a corresponding wheel speed change, the
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
POSSIBLE CAUSES
SENSOR OR TONE WHEEL CONCERN
DTC INTERMITTENT
RIGHT REAR WHEEL SPEED SENSOR INOPERATIVE
INTERMITTENT SIGNAL DTC
TEST ACTION APPLICABILITY
1 With the DRBIIIt, erase DTCs.
Turn the ignition off.
Start the engine.
Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph).
Using the DRBIIIt, monitor the Right Rear Wheel Speed Sensor while an assistant
drives the vehicle.
With the DRBIIIt, monitor all wheel speed sensors.
Is Right Rear WSS Signal 0 km/h (0 mph) or differing from others by more than 5
km/h (3 mph)?All
Ye s®Go To 2
No®Go To 3
2 Inspect the Right Rear Wheel Speed Sensor, Connector and Tone Wheel.
NOTE: Inspect components for damage and correct installation.
Are there any visible Sensor, Connector or Tone Wheel concerns?All
Ye s®Correct the sensor, connector or tone wheel concern as necessary.
The vehicle must be driven at 25 km/h (15 mph) to extinguish the
ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
No®Replace the Left Rear Wheel Speed Sensor in accordance with the
Service Information. The vehicle must be driven at 25 km/h (15
mph) to extinguish the ABS indicator.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)

Symptom:
SYSTEM OVERVOLTAGE
When Monitored and Set Condition:
SYSTEM OVERVOLTAGE
When Monitored: Ignition on. The CAB monitors the Fused B(+) circuit at all times for
proper system voltage.
Set Condition: If the voltage is above 16.5 volts for greater than 420 milliseconds (ms),
the Diagnostic Trouble Code (DTC) is set.
POSSIBLE CAUSES
BATTERY OVERCHARGED
FUSED IGNITION SWITCH OUTPUT HIGH
GROUND CIRCUIT OPEN
CAB - INTERNAL FAULT
INTERMITTENT DTC
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase DTC's.
Turn the ignition off.
Turn the ignition on.
Start the engine.
With the DRBIIIt, read DTC's.
Does the DRBIIItdisplay System Overvoltage DTC?All
Ye s®Go To 2
No®Go To 6
2 Turn the ignition off.
Inspect for battery charger connected to battery.
Is a battery charger connected to the battery?All
Ye s®Charge battery to proper level. Disconnect the battery charger.
Clear DTC's.
Perform ABS VERIFICATION TEST - VER 1.
No®Go To 3
28
BRAKES (CAB)