service CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
2WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORM-
ING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater Assist C1 harness connector.
Turn the ignition on.
Measure the voltage between the Cabin Heater Assist Control circuit and ground.
Is there any voltage present?All
Ye s®Go To 3
No®Replace the FCM in accordance with the Service Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
3WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORM-
ING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Turn the ignition off.
Disconnect the battery in accordance with the Service information.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the IPM C3 harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater Assist C1 and C2 harness connectors.
Measure the resistance between the Cabin Heater Assist Control circuit and the
Fused B(+) circuit.
Is the resistance below 10K ohms?All
Ye s®Repair the Cabin Heater Assist Control circuit for a short to the
Fused B(+) circuit.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Go To 4
330
CABIN HEATER
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE) Ð
Continued

TEST ACTION APPLICABILITY
4WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORM-
ING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Turn the ignition off.
Disconnect the battery in accordance with the Service Information.
Remove the FCM in accordance with the Service Information.
Reconnect the IPM C3 harness connector.
Reconnect the battery in accordance with the Service Information.
Turn the ignition on.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater Assist C1 harness connector.
Measure the voltage between the Cabin Heater Assist Control circuit and ground.
Is there any voltage present?All
Ye s®Repair the Cabin Heater Assist Control circuit for a short to
voltage.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Replace the FCM in accordance with the Service Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
331
CABIN HEATER
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE) Ð
Continued

TEST ACTION APPLICABILITY
3WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
Turn the ignition on.
With the DRBIIIt, check for FCM and HVAC DTCs.
Does the DRBIIItdisplay any FCM or HVAC DTCs?All
Ye s®For FCM DTCs, return to the symptom list and choose the
symptom(s). Also, refer to Intelligent Power Module for related
symptom(s). For HVAC DTCs, refer to Heater & A/C for related
symptom(s).
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Go To 4
4WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
Start the engine.
Allow the engine to idle.
Turn the A/C - Heater Control Module's Power switch on.
Turn the Blower switch to the high speed position.
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.
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.
With the DRBIIItin HVAC, Systems Tests, select Diesel Cabin Heater Test and press
#1.
With the DRBIIItin HVAC, Systems Tests, Diesel Cabin Heater Test, read the Cabin
Heater Status.
Does the Status display: On?All
Ye s®Replace the FCM in accordance with the Service Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
333
CABIN HEATER
*CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE Ð
Continued

Symptom:
*KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT
OPERATING PROPERLY
POSSIBLE CAUSES
DRIVER DOOR AJAR STATUS
IGNITION SWITCH
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 Open the driver door.
With the DRB, in Input/Outputs, read the9DR DOOR AJAR SW9state.
Does the DRB display9DR DOOR AJAR SW: CLOSED9?All
Ye s®Go To 2
No®Refer to symptom list for problems related to Door Ajar.
Perform BODY VERIFICATION TEST - VER 1.
2 With the DRBIIItin Inputs/Outputs, read the Key in Ign Sw state while inserting
the key in and out of the ignition switch.
Does the DRBIIItdisplay change from open to closed?All
Ye s®Replace and program the Body Control Module in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Check the Ignition Lock Cylinder for damage. If OK replace the
Ignition Switch.
Perform BODY VERIFICATION TEST - VER 1.
336
CHIME

Symptom:
*PROBLEM WITH THE HIGH VEHICLE SPEED WARNING CHIME
POSSIBLE CAUSES
INCORRECT COUNTRY CODE PROGRAMMED IN BCM
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 Note: The high speed warning chime is for Gulf Coast Countries only.
With the DRBIIItin Miscellaneous check the Body Control Module country code
setting.
Is the country code incorrect?All
Ye s®Program the correct country code setting.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace and program the Body Control Module in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
337
CHIME

POSSIBLE CAUSES
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1NOTE: For this code to be active, the DRB will not be able to communicate
with any modules on the vehicle (except the PCM).
NOTE: If this code is set and active it will be necessary to perform the PCI
Bus Communication Failure symptom.
WARNING: 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, wiggle the wiring
harnesses. This is to try and duplicate the complete bus failure condition.
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.
341
COMMUNICATION
BCM, PCI BUS SHORTED TO BATTERY ÐContinued

Symptom:
FCM, PCM COMMUNICATION FAULT
When Monitored and Set Condition:
FCM, PCM COMMUNICATION FAULT
When Monitored: With the ignition in run, and the IOD fuse installed.
Set Condition: The FCM does not receive any messages from the PCM for at least 5
seconds.
POSSIBLE CAUSES
PCM COMMUNICATION FAULT
ATTEMPT TO COMMUNICATE WITH THE PCM
PCI BUS CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRB, enter Instrument Cluster, System Tests then PCM Monitor.
Does the DRB display: PCM is active on BUS?All
Ye s®Erase the DTC, if DTC resets, replace the Front Control Module.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 2
2 Turn the ignition on.
With the DRB, attempt to communicate with the PCM.
Was the DRB able to communicate with the PCM?All
Ye s®Go To 3
No®Refer to the communication category and perform the appropriate
symptom.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the PCM C2 harness connector.
Connect the diagnostic junction port tester #8339 to the diagnostic junction port.
Note: Do not connect the tester to the DRB.
Measure the resistance of the PCI Bus circuit between the diagnostic junction port
tester and the PCM C2 connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the PCI Bus circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
347
COMMUNICATION

Symptom:
PCM MESSAGES NOT RECEIVED
When Monitored and Set Condition:
PCM MESSAGES NOT RECEIVED
When Monitored: With the ignition in run, and the IOD fuse installed.
Set Condition: The BCM does not receive any messages from the PCM for at least 5
seconds.
POSSIBLE CAUSES
PCM MESSAGE NOT RECEIVED
ATTEMPT TO COMMUNICATE WITH THE PCM
PCI BUS CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRB, enter Instrument Cluster, System Tests then PCM Monitor.
Does the DRB display: PCM is active on BUS?All
Ye s®Erase the DTC, if DTC resets, replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 2
2 Turn the ignition on.
With the DRB, attempt to communicate with the PCM.
Was the DRB able to communicate with the PCM?All
Ye s®Go To 3
No®Refer to the communication category and perform the appropriate
symptom.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the PCM C2 harness connector.
Connect the diagnostic junction port tester #8339 to the diagnostic junction port.
Note: Do not connect the tester to the DRB.
Measure the resistance of the PCI Bus circuit between the diagnostic junction port
tester and the PCM C2 connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the PCI Bus circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
367
COMMUNICATION

Symptom:
*BUS +/- SIGNALS OPEN FROM AUTOMATIC TEMPERATURE
CONTROL MODULE
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE BCM
GROUND CIRCUIT OPEN
FUSED (B+) CKT OPEN
IGNITION SWITCH CIRCUIT OPEN
OPEN PCI BUS CIRCUIT
AUTOMATIC TEMPERATURE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRB, enter Body then Body Computer.
Was the DRB able to I/D or communicate with the BCM?All
Ye s®Go To 2
No®Refer to the symptom list for problems related to no communica-
tion with the BCM.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition off.
Disconnect the ATC C2 harness connector.
Measure the resistance between ground and the ground circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Repair the Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the ATC C2 harness connector.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit.
Is the test light illuminated?All
Ye s®Go To 4
No®Repair the Fused B+ circuit for an open or short. Refer to the
wiring diagrams in the service information.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the ATC C2 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Ignition Switch circuit.
Is the test light illuminated?All
Ye s®Go To 5
No®Repair the Ignition Switch circuit for an open or short. Refer to
the wiring diagrams in the service information.
Perform BODY VERIFICATION TEST - VER 1.
373
COMMUNICATION

TEST ACTION APPLICABILITY
5Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptom list from the menu
and repair as necessary.
Disconnect the SKIM harness connector.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
Select DRB Standalone.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Press F2 again
when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the SKIM connector.
Turn the ignition on.
Observe the voltage display on the DRB Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?All
Ye s®Go To 6
No®Repair the PCI Bus circuit for an open.
Perform SKIS VERIFICATION.
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Sentry Key Immobilizer Module in
accordance with the Service Information.
Perform SKIS VERIFICATION.
378
COMMUNICATION
*BUS +/- SIGNALS OPEN FROM SENTRY KEY IMMOBILIZER MODULE
Ð
Continued