battery CHRYSLER VOYAGER 2001 Service Manual

Symptom:
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES
POSSIBLE CAUSES
AIRBAG INDICATOR ON WITHOUT TROUBLE CODES
INSTRUMENT CLUSTER PROBLEMS
TEST ACTION APPLICABILITY
1 Turn the ignition on.
Make sure that all active DTCS have been repaired before pre forming this
procedure.
With the DRBIII select PASSIVE RESTRAINTS, AIRBAG, MONITOR DISPLAY,
WARNING LAMP STATUS and read the WARNING LAMP STATUS.
Does the DRB show LAMP REQ BY ACM: ON?All
Ye s®Replace the Occupant Restraint Controller in accordance with
Service Instructions. WARNING: make sure the battery is dis-
connected and wait 2 minutes before proceeding.
Perform AIRBAG VERIFICATION TEST - VER 1.
No®Refer to INSTRUMENT CLUSTER CATEGORY symptom list for
problems related to Instrument Cluster.
Perform AIRBAG VERIFICATION TEST - VER 1.
NOTE: When reconnecting Airbag system components, the ignition must be
turned off and the battery must be disconnected.
188
AIRBAG

Symptom List:
NBS OUTPUT 1 SHORT TO BATT
NBS OUTPUT 2 SHORT TO BATT
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be NBS OUTPUT 1 SHORT TO
BATT.
When Monitored and Set Condition:
NBS OUTPUT 1 SHORT TO BATT
When Monitored: With the ignition on and the Radio on.
Set Condition: The FCM detects excessive current when attempting to close the NBS
relay.
NBS OUTPUT 2 SHORT TO BATT
When Monitored: With the ignition on and the Radio on.
Set Condition: The FCM detects excessive current when attempting to close the NBS
relay.
POSSIBLE CAUSES
CHECK DTCS
NBS RELAY SHORTED
NBS RELAY CONTROL CIRCUIT SHORTED TO BATTERY
FRONT CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
Turn the Radio 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 NBS Output 1 Short to Batt and the NBS Output 2 Short to Batt DTC's
set?All
Ye s®Go To 2
No®Replace the Front Control Module in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
209
AUDIO

Symptom:
REMOTE RADIO SWITCH STUCK
When Monitored and Set Condition:
REMOTE RADIO SWITCH STUCK
When Monitored: With the ignition on.
Set Condition: The code will set if the BCM detects a stuck switch or a short to ground on
the Radio Control MUX circuit for more than 10 seconds.
POSSIBLE CAUSES
INTERMITTENT CONDITION
LEFT REMOTE RADIO SWITCH SHORTED TO GROUND
RIGHT REMOTE RADIO SWITCH SHORTED TO GROUND
RADIO CONTROL MUX CIRCUIT SHORTED TO GROUND AT THE SWITCH
RADIO CONTROL MUX CIRCUIT SHORTED TO THE RETURN CIRCUIT AT THE SWITCH
CLOCKSPRING SHORTED TO GROUND
RADIO CONTROL MUX CIRCUIT SHORTED TO GROUND
RADIO CONTROL MUX CKT SHORTED TO THE RADIO CONTROL MUX RETURN CKT
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 With the DRB, erase DTC's.
Cycle the ignition switch from off to on and wait approximately 1 minute.
With the DRB, read DTC's.
Did this DTC reset?All
Ye s®Go To 2
No®Refer to the wiring diagrams located in the service information to
help isolate a possible intermittent short.
Perform BODY VERIFICATION TEST - VER 1.
2WARNING: Turn the ignition off, disconnect the battery and wait 2 minutes
before proceeding.
CAUTION: Do not place an intact undeployed airbag module face down on
a hard surface, the airbag module will propel into the air if accidently
deployed.
Remove the Driver Airbag Module.
Disconnect the Left Remote Radio Switch harness connector.
Turn the ignition on, reconnect the battery.
With the DRB, enter Body Computer then Sensors and monitor the Radio Control SW
voltage
Is the voltage approximately 5.0 volts?All
Ye s®Replace the Left Remote Radio Switch.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 3
219
AUDIO

TEST ACTION APPLICABILITY
3WARNING: Turn the ignition off, disconnect the battery and wait 2 minutes
before proceeding.
CAUTION: Do not place an intact undeployed airbag module face down on
a hard surface, the airbag module will propel into the air if accidently
deployed.
Remove the Driver Airbag Module.
Disconnect the Right Remote Radio Switch harness connector.
Turn the ignition on, reconnect the battery.
With the DRB, enter Body Computer then Sensors and monitor the Radio Control SW
voltage
Is the voltage approximately 5.0 volts?All
Ye s®Replace the Right Remote Radio Switch.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 4
4 Turn the ignition off.
Disconnect the Clockspring C4 harness connector.
Turn the ignition on.
With the DRB, enter Body Computer then Sensors and monitor the Radio Control SW
voltage.
Is the voltage approximately 5.0 volts?All
Ye s®Go To 5
No®Go To 6
5 Turn the ignition off.
Disconnect the Clockspring C4 harness connector.
NOTE: Ensure both remote radio switches are disconnected.
Measure the resistance between ground and each Radio Control MUX circuit at the
clockspring C4 harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Radio Control MUX circuit for a short to ground
between the clockspring and the remote radio switches.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the Radio Control MUX circuit for a short to the Radio
Control MUX Return circuit between the clockspring and the
remote radio switches.
Perform BODY VERIFICATION TEST - VER 1.
6 Turn the ignition off.
Disconnect the Clockspring C1 harness connector.
Turn the ignition on.
With the DRB, enter Body Computer then Sensors and monitor the Radio Control SW
voltage.
Is the voltage approximately 5.0 volts?All
Ye s®Replace the Clockspring.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 7
220
AUDIO
REMOTE RADIO SWITCH STUCK ÐContinued

Symptom:
EEPROM CHECKSUM ERROR (ACTIVE)
When Monitored and Set Condition:
EEPROM CHECKSUM ERROR (ACTIVE)
When Monitored: Ignition in RUN and IOD fuse installed after a battery disconnect.
Set Condition: This DTC is set if the calibrated check sum does not match the stored
value.
POSSIBLE CAUSES
ATC - EEPROM CHECKSUM ERROR
TEST ACTION APPLICABILITY
1 When this code is present, the ATC must be replaced.
View repair.All
Repair
Replace the ATC.
With the DRBIIIt, reset the ATC after repair/replacement is
complete.
Perform BODY VERIFICATION TEST - VER 1.
240
AUTOMATIC TEMPERATURE CONTROL

Symptom List:
CABIN HEATER PRE-TEST
CABIN HEATER CONTROL CIRCUIT OPEN (STORED)
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY
(STORED)
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be A. CABIN HEATER PRE-TEST.
When Monitored and Set Condition:
CABIN HEATER CONTROL CIRCUIT OPEN (STORED)
When Monitored: When the DCHA system is off.
Set Condition: The DCHA Low Side Driver inside the FCM expects to see a system
voltage of 13.8 volts through the DCHA relay coil when the DCHA system is off. This DTC
will set if the FCM sees a voltage below 3.5 volts on the Cabin Heater Assist Control circuit
during this time.
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (STORED)
When Monitored: During DCHA activation and operation.
Set Condition: This DTC will set if the FCM sees between 5.0 and 15.0 volts on the Cabin
Heater Assist Control circuit.
POSSIBLE CAUSES
NO RESPONSE FROM CABIN HEATER MODULE
DTC(S) PRESENT
CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE
STORED DCHA DTC(S) TEST COMPLETE
TEST ACTION APPLICABILITY
1WARNING: 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, attempt to communicate with the Cabin Heater Module.
Does the DRBIIItdisplay: No Response From Cabin Heater Module?All
Ye s®Refer to Communication for the related symptom.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Go To 2
296
CABIN HEATER

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.
NOTE: The DCHA Control will store up to three DTCs in its memory.
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.
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 occur-
rence.
Turn the ignition on.
Set the Blend Control to the max cool position.
Turn the A/C - Heater Control Module's Power switch off.
With the DRBIIIt, record and erase Cabin Heater and FCM DTCs.
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 DCHA Field Mode 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 Cabin Heater, Systems Tests, select Field Mode and press Enter.
Set the Blend Control to the max heat position. Upon completion of the Field Mode
Test, proceed as follows:
With the DRBIIIt, read Cabin Heater and Active FCM DTCs.
Turn the Blower switch off and turn the A/C - Heater Control Module's Power switch
off.
Turn the engine off.
Are any DTCs present?All
Ye s®Return to the symptom list and choose the DTC(s). Diagnose and
repair all FCM faults prior to diagnosing DCHA faults. If DTC
B1813 Heater In Lockout Mode reset with other DTC(s), reset the
heater before diagnosing the other DTC(s).
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Go To 5
5 Is the symptom Cabin Heater inoperable from the A/C - Heater Module? All
Ye s®Refer to symptom *Cabin Heater Inoperable From A/C - Heater
Module in the Cabin Heater category.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Let DCHA cool. Inspect fuel line, intake & exhaust, & coolant
hoses for restrictions, obstructions, loose clamps, leakage, etc.
Check connectors. Clean & repair as necessary. Refer to Service
Manual for additional symptom based diagnosis, if necessary.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
298
CABIN HEATER
CABIN HEATER PRE-TEST ÐContinued

Symptom:
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESH-
OLD
When Monitored and Set Condition:
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD
When Monitored: With the engine running.
Set Condition: This DTC will set if the DCHA's power supply voltage drops below 10.0
volts for longer than 20 seconds.
POSSIBLE CAUSES
FIELD MODE TEST RUN WITH THE ENGINE OFF
VEHICLE'S BATTERY SYSTEM
VEHICLE'S CHARGING SYSTEM NOT OPERATING PROPERLY
DCHA CONTROL UNIT FAULT
FUSED B+ CIRCUIT HIGH RESISTANCE
DCHA CONTROL UNIT FAULT
TEST ACTION APPLICABILITY
1WARNING: 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.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE CABIN HEATER PRE-TEST. ALWAYS PERFORM THE CABIN HEATER
PRE-TEST PRIOR TO PERFORMING ANY OTHER CABIN HEATER TEST
FOR THE RESULT TO BE VALID.
Was the Field Mode Test run with the engine off?All
Ye s®Rerun the Field Mode Test exactly as it is described in Test 4 of
the Cabin Heater Pre-Test. If DTC B1802 resets, Go To Test #2 of
this symptom. Otherwise, perform other diagnosis and testing as
necessary.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Go To 2
304
CABIN HEATER

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.
Turn the ignition off.
Inspect the vehicle's battery terminals, cable terminals, and cables for corrosion and
damage in accordance with the Service Information.
Test the vehicle's battery in accordance with the Service Information.
Is the vehicle's battery system Ok?All
Ye s®Go To 3
No®Clean/repair the vehicle's battery system 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.
Check the vehicle's charging system for proper operation in accordance with the
Service Information.
Is the vehicle's charging system operating properly?All
Ye s®Go To 4
No®Repair the vehicle's charging system in accordance with the
Service Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
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 on.
With the DRBIIItin Sensors, record the DCHA Operating Voltage.
Disconnect the Cabin Heater Assist C1 harness connector.
Measure the voltage between the Fused B+ circuit and ground.
Is there more than 1.0 volt difference between the Operating Voltage and the Fused
B+ voltage?All
Ye s®Replace the DCHA Heater Module in accordance with the Service
Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Go To 5
305
CABIN HEATER
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD Ð
Continued

TEST ACTION APPLICABILITY
5WARNING: 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.
Make sure that the Cabin Heater Assist C1 harness connector is connected to the
DCHA.
Connect a suitable voltmeter to the vehicle's battery. Position the voltmeter where it
can be monitored while operating the DRBIIIt.
Turn the ignition on.
Set the Blend Control to the max cool position.
Turn the A/C - Heater Control Module's Power switch off.
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 DCHA Field Mode 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 Cabin Heater, Systems Tests, select Field Mode and press Enter.
Set the Blend Control to the max heat position.
With the DRBIIItin Sensors, monitor the DCHA Operating Voltage and the
voltmeter while the Field Mode Test is running. Upon completion of the Field Mode
Test proceed as follows:
Turn the Blower switch off and turn the A/C - Heater Control Module's Power switch
off.
Turn the engine off.
Was there more than 1.5 volts difference between Operating & battery voltage during
the test?All
Ye s®Repair the high resistance in the Fused B+ circuit.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Replace the DCHA Heater Module in accordance with the Service
Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
306
CABIN HEATER
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD Ð
Continued