ad blue CHRYSLER VOYAGER 2001 User Guide

TABLE OF CONTENTS - Continued
SERIAL LINK EXTERNAL FAULT.........................................216
ROLLING CODE FAILURE...............................................218
VIN MISMATCH........................................................218
TRANSPONDER COMMUNICATION FAILURE..............................220
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE.............220
TRANSPONDER ID MISMATCH..........................................220
TRANSPONDER RESPONSE MISMATCH..................................220
VERIFICATION TESTS
VERIFICATION TESTS..................................................223
8.0 COMPONENT LOCATIONS..............................................227
8.1CONTROL MODULES.............................................227
8.2CONTROLS AND SOLENOIDS......................................227
8.3DATA LINK CONNECTOR..........................................227
8.4FUEL SYSTEM...................................................228
8.5RELAYS.........................................................228
8.6SENSORS.......................................................229
8.7SWITCHES......................................................230
9.0 CONNECTOR PINOUTS................................................231
A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY............................231
A/C PRESSURE SENSOR - GRAY 4 WAY..................................231
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY........231
BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY................231
BOOST PRESSURE SENSOR (DIESEL) - BLACK 4 WAY.....................232
BRAKE LAMP SWITCH - BLACK 6 WAY...................................232
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY...................232
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY...................232
CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY................232
DATA LINK CONNECTOR - BLACK 16 WAY................................233
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY...............................233
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY..................234
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY..................235
ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY..................236
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY.................236
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY.................237
ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY.............237
FUEL HEATER (DIESEL) - BLACK 2 WAY..................................237
FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY...........................237
FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAY...........................237
FUEL INJECTOR NO. 3 (DIESEL) - BLACK 2 WAY...........................238
FUEL INJECTOR NO. 4 (DIESEL) - BLACK 2 WAY...........................238
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY.......................238
FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY.....................238
GENERATOR - BLACK 2 WAY...........................................238
GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY.............................239
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY.........239
LEFT SPEED CONTROL SWITCH - WHITE 2 WAY..........................239
LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY..............................239
MASS AIR FLOW SENSOR (DIESEL) - ORANGE 5 WAY......................240
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TABLE OF CONTENTS - Continued
A/C COMPRESSOR CLUTCH RELAY......................................242
ECM/PCM RELAY (DIESEL).............................................242
FUEL HEATER RELAY (DIESEL)..........................................242
LIFT PUMP RELAY (DIESEL).............................................242
STARTER MOTOR RELAY...............................................242
RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY.............................242
RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAY.............................243
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY......................243
RADIATOR FAN RELAY NO. 2 (DIESEL) - BLUE 9 WAY......................243
RADIATOR FAN RELAY NO. 3 (DIESEL) - BLUE 9 WAY......................243
RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY.........................244
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY......................244
VEHICLE SPEED SENSOR (MTX/ATX) - BLACK 3 WAY......................244
WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY........................244
10.0 SCHEMATIC DIAGRAMS................................................245
10.12001 RG 2.5L TURBO DIESEL......................................245
11.0 CHARTS AND GRAPHS................................................247
vi

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 - -
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAYCAV CIRCUIT FUNCTION
1 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K900 20DB/DG SENSOR GROUND
C
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236
CONNECTOR PINOUTS

RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAYCAV CIRCUIT FUNCTION
1 Z823 12BK GROUND
2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAYCAV CIRCUIT FUNCTION
1- -
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5- -
6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
7- -
8 A201 12RD/LG FUSED B(+)
9- -
RADIATOR FAN RELAY NO. 2 (DIESEL) - BLUE 9 WAYCAV CIRCUIT FUNCTION
1- -
2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5- -
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
7- -
8 A112 12OR/RD FUSED B(+)
9- -
RADIATOR FAN RELAY NO. 3 (DIESEL) - BLUE 9 WAYCAV CIRCUIT FUNCTION
1- -
2 Z823 12BK GROUND
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
7- -
8 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
9- -
C
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243
CONNECTOR PINOUTS

- 31TH/OIL PUMP - STANDARD PROCEDURE)
(Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - 41TE/OIL PUMP - STANDARD PRO-
CEDURE)
(b) If oil pump volume is within specification, a
possible restriction in the cooler lines or cooler has
occurred.
(c) If oil pump volume is not within specification,
possible internal transmission restrictions, compo-
nent wear or damage has occurred. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH - DIAGNOSIS AND TESTING) (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
41TE - DIAGNOSIS AND TESTING)
(d) If an oil cooler restriction is suspected, per-
form further inspections and flow meter testing by
isolating components (i.e. lines, coolers).
(e) After a restriction is isolated, perform cooler
flush procedure. (Refer to 7 - COOLING/TRANS-
MISSION - STANDARD PROCEDURE)
(f) Re-test cooler flow. If cooler flow does not
exceed minimum specification, replace compo-
nent(s) as necessary.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
The recommended procedure for cooler flushing is
to use Tool 6906 Cooler Flusher.
WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.1±1968.
WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Use MopartTransmission Cooler Flush (MS-552) or
equivalent solution conforming to MS-552. Flushing
solvents are petroleum based solutions generally
used to clean automatic transmission components.
DO NOTuse solvents containing acids, water, gaso-
line, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(4) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(5) Connect the CLEAR return line to the INLET
(To) cooler line
(6) Turn pump ON for two to three minutes to
flush cooler and lines.
(7) Turn pump OFF.
(8) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(9) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(10) Place CLEAR suction line into a one quart
container of MopartATF+4 (Automatic Transmission
FluidÐType 9602).
(11) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(12) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
RSTRANSMISSION7-37
TRANSMISSION (Continued)

A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z153 18BK/GY GROUND
A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAY
CAV 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 WAY
CAV 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
8Wa - 80 - 6 8W-80 CONNECTOR PIN-OUTSRG

C307 - GRAY (SEAT SIDE)
CAV CIRCUIT
1 Z848 18BK/OR (POWER/HEATED SEAT)
2 R58 18LB/GY
3 R60 18LB/TN
4 P8 20LG/WT (HEATED SEAT)
5 A210 14OR/RD (POWER/HEATED SEAT)
6 F503 20WT/PK (HEATED SEAT)
7-
8-
9-
10 -
11 -
12 -
C308 - BLUE (LEFT DOOR WIRE TRACK
ASSEMBLY SIDE)
CAV CIRCUIT
1 Z825 14BK (POWER SLIDING DOOR)
1 Z77 20BK (MANUAL SLIDING DOOR)
2 P32 20BK/TN
3 G77 20BK/DG
4 P5 20BK/DB
5-
6-
7 G151 20BK/GY (POWER SLIDING
DOOR)
8 D25 20BK/VT (POWER SLIDING DOOR)
9-
10 A113 14BK/RD (POWER SLIDING
DOOR)
C308 - BLUE (BODY SIDE)
CAV CIRCUIT
1 Z825 14BK/WT (BUILT-UP-EXPORT
MANUAL SLIDING DOOR) (POWER
SLIDING DOOR)
1 Z77 20BK/GY (EXCEPT BUILT-UP-EX-
PORT MANUAL SLIDING DOOR)
2 P32 20TN/VT
3 G77 20VT/GY
4 P5 20TN/OR
5-
6-
7 G151 20VT/BR (POWER SLIDING
DOOR)
8 D25 20WT/VT (POWER SLIDING
DOOR)
9-
10 A113 12WT/RD (POWER SLIDING
DOOR)
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-31

ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY
CAV 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 - -
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K900 20DB/DG SENSOR GROUND
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-57

FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K342 16BR/WT ECM/PCM RELAY OUTPUT
2 K87 16BR FUEL PRESSURE SOLENOID CONTROL
FUEL PUMP MODULE - LT. GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 Z201 16BK/OR (GAS) GROUND
2 Z201 18BK/OR (RHD/DIESEL) GROUND
2 Z201 20BK/DB (LHD/DIESEL) (GAS) GROUND
3 N4 18DB/WT FUEL LEVEL SENSOR SIGNAL
4 N1 16DB/OR (GAS) FUEL PUMP RELAY OUTPUT
GENERATOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
1 K342 16BR/WT (GAS) AUTOMATIC SHUTDOWN RELAY OUTPUT
2 K20 18BR/GY (GAS) GENERATOR FIELD CONTROL
2 K20 14BR/GY (DIESEL) GENERATOR FIELD CONTROL
GLOVE BOX LAMP - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 M28 20YL/TN GLOVE BOX LAMP DRIVER
2 Z328 20BK/TN GROUND
GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 A202 10RD/WT FUSED B(+)
2 K152 20DB/WT GLOW PLUG RELAY CONTROL
3 K342 16BR/WT ECM/PCM RELAY OUTPUT
4 K154 10BR/OR GLOW PLUG RELAY OUTPUT
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-63

HALO LAMP - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 Z326 20BK/OR GROUND
2 M26 20YL/DB HALO LAMP DRIVER
HEADLAMP SWITCH - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1 Z403 20BK/YL (BUILT-UP-EXPORT) GROUND
2 L78 20WT/OR (BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT
3- -
4 Z407 18BK/OR GROUND
5 L36 20WT/DB (BUILT-UP-EXPORT) REAR FOG LAMP INDICATOR DRIVER
6 L900 20WT/YL HEADLAMP SWITCH MUX RETURN
7 L13 20WT/YL (BUILT-UP-EXPORT) HEADLAMP ADJUST SIGNAL
8 E19 20OR/BR PANEL LAMPS DRIVER (HEADLAMP SWITCH)
9- -
10 L39 20WT/OR (HIGH LINE) FRONT FOG LAMP INDICATOR DRIVER
11 L307 20WT/BR HEADLAMP SWITCH MUX
12 E2 20OR/BR PANEL LAMPS DIMMER SIGNAL
13 - -
HEADLAMP WASHER PUMP MOTOR (BUILT-UP-EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 V53 12BR/OR HEADLAMP WASHER RELAY OUTPUT
2 Z243 12BK/OR GROUND
HIGH NOTE HORN - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z299 18BK/OR GROUND
2 X2 18DG/OR HORN RELAY OUTPUT
8Wa - 80 - 64 8W-80 CONNECTOR PIN-OUTSRG