diesel CHRYSLER VOYAGER 2001 User Guide
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2001, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2001Pages: 4284, PDF Size: 83.53 MB
Page 46 of 4284
± Evap Temp Sensor Shorted
± Evap Temp Sensor Open
± A/C Pressure Too Low
± A/C Pressure Too High
± Invalid Conditions for Cooldown Test, Evap
Temperature Too Low
If a message other than Cooldown Test Passed
occurs, refer to the appropriate symptom for diag-
nosis.
3.9.1.7 ACTIVE AND STORED TROUBLE
CODES
The Automatic Temperature Control (ATC) is
capable of storing Active and Stored trouble codes.
Active codes indicate a current fault in the system.
Stored codes indicate that a problem has occurred
in the system, however is not currently present.
Active codes cannot be erased until the problem
causing the code has been repaired. At this time the
Active code is converted to a Stored code, which can
be erased using the DRBIIIt.
3.9.2 MANUAL TEMPERATURE CONTROL
3.9.2.1 SYSTEM AVAILABILITY
Depending on the model, either a Single-Zone Air
Conditioning System or a Dual-Zone Air Condition-
ing System is currently available in these vehicles.
3.9.2.2 CABIN HEATER
For Vehicles equipped with a diesel engine, a
Cabin Heater is used in conjunction with the HVAC
system. The Cabin Heater is designed to supply the
vehicle's occupants with heat prior to the engine
reaching operating temperature. For additional in-
formation on this system, refer to Cabin Heater
under General Information and Diagnostic Proce-
dures in this manual.
3.9.2.3 ZONE CONTROL ± SINGLE-ZONE
The Single-Zone Air Conditioning System main-
tains incoming air temperature, airflow, fan speed,
and fresh air intake for the entire vehicle from the
instrument panel mounted A/C ± Heater Control
Module. The full range of temperature that the
system can produce in any mode for the entire
vehicle is available by positioning the blend control
to the desired range.
3.9.2.4 ZONE CONTROL ± DUAL-ZONE
The Dual-Zone Air Conditioning System main-
tains incoming air temperature, airflow, fan speed,
and fresh air intake for the entire vehicle from the
instrument panel mounted A/C ± Heater ControlModule. In addition, this system provides com-
pletely independent side-to-side control of incoming
air temperature. The full range of temperature that
the system can produce in any mode is available on
either side of the vehicle by positioning the inde-
pendent driver and passenger blend controls to the
desired range.
3.9.2.5 AIR DISTRIBUTION
The HVAC unit has five fully adjustable instru-
ment panel outlets. Side-window demister outlets
in the instrument panel eliminate door ducts and
door-to-instrument panel seals. A single, central
mounted outlet delivers air for defrosting the wind-
shield. Air exhausters allow air entering at the
front of the vehicle to flow out the back to the rear
occupants. Mid-cabin comfort control directs only
cooling air flow to the intermediate seat occupants
through outlets at the rear of each front door trim
panel. Air is supplied to these outlets from the
instrument panel through ducts in the doors that
use molded seals at the instrument panel to prevent
air leakage. Wide outlets under the front seats with
directional dividers distribute heated air across the
floor to the intermediate seat occupants. Ducts in
the center of the vehicle under the carpet deliver air
from the HVAC unit to these outlets. Models
equipped with Dual-Zone A/C systems also include
a dust and odor air filter installed in the HAVC
housing.
3.9.2.6 DOOR ACTUATORS
The electric door actuators are a two-wire design.
Each door actuator uses a similar connector wired
directly to the A/C ± Heater Control Module. Single-
Zone systems have one blend door actuator, one
mode door actuator, and one recirculation door
actuator. Dual-Zone systems have two blend door
actuators, one mode door actuator, and one recircu-
lation door actuator. All of the door actuators are
accessible from the vehicle's interior.
3.9.2.7 DOOR ACTUATOR CONTROL
The A/C ± Heater Control Module knows the
number of operating actuator revolutions required
for full door travel as well as the number of actuator
commutator pulses per revolution. Using these pa-
rameters, the A/C ± Heater Control Module runs
the actuator for the number of commutator pulses
that correspond to the desired door position. To
maintain accuracy, the system recalibrates itself
periodically at known zero and full travel condi-
tions.
17
GENERAL INFORMATION
Page 47 of 4284
3.9.2.8 HVAC SYSTEM RELAYS
The Integrated Power Module (IPM) houses and
provides power to the A/C Clutch Relay and Front
Blower Motor Relay.
3.9.2.9 EVAPORATOR TEMPERATURE
SENSOR
An evaporator temperature sensor, located on the
A/C expansion valve under the hood, replaces the
previously used fin sensor.
3.9.2.10 A/C ± HEATER CONTROL
MODULE, SWITCH OPERATION
Power Switch
The Power Switch is a momentary contact switch.
The switch LED illuminates when the switch is on.
The Power Switch setting is remembered during
power down.
Rear Window Defogger Switch
The Rear Window Defogger Switch is a momen-
tary contact switch. Toggling the switch results in
the A/C ± Heater Control Module sending a change
of state message to the FCM to provide rear window
defogger activation or deactivation respectively.
The switch LED illuminates when the switch is on.
Recirculation Switch
The Recirculation Switch is a momentary contact
switch. Toggling the switch on results in the A/C ±
Heater Control Module signaling the actuator to
close the fresh-air door. Toggling the switch off
results in the A/C ± Heater Control Module signal-
ing the actuator to open the fresh-air door. The
switch LED illuminates when the switch is on.
When the Power Switch is off, the A/C ± Heater
Control Module closes the fresh-air door to prevent
outside air from entering the passenger compart-
ment. The recirculation mode will cancel whenever
defrost is requested. Pressing the Recirculation
Switch while in defrost mode will illuminate the
Recirculation Switch LED, but only while the but-
ton is pressed. Under this circumstance, the recir-
culation request will be denied and the fresh-air
door will remain in the fresh position. All door
positions are determined relative to the number of
commutator pulses required to provide full travel of
the door. On command, the A/C ± Heater Control
Module runs the actuator for the number of pulses
corresponding to the desired door position.
A/C Switch
The A/C Switch is a momentary contact switch.
Toggling the switch results in the A/C ± Heater
Control Module sending a change of state message
to the Powertrain Control Module (PCM ± gasoline)or Engine Control Module (ECM ± diesel) to provide
A/C compressor clutch activation or deactivation
respectively. The A/C ± Heater Control Module will
only provide this request if EVAP function is found
acceptable. The Power Switch must be on to make
the A/C switch active. The switch LED illuminates
when the switch is on. The A/C Switch setting is
remembered during power down.
Blower Switch
The rotary Blower Switch has five positions, Low,
M1, M2, M3, and High. The Power Switch must be
on to make the Blower Switch active. Toggling the
Power Switch results in the A/C ± Heater Control
Module sending a request to the FCM to provide
blower motor activation or deactivation respec-
tively.
Blend Switch ± Single Zone
The single rotary Blend Switch has multiple
detents to control the full range of temperature that
the system can produce in any mode. Rotating the
switch results in the A/C ± Heater Control Module
signaling the actuator to move the blend door. All
door positions are determined relative to the num-
ber of commutator pulses required to provide full
travel of the door. On command, the A/C ± Heater
Control Module runs the actuator for the number of
pulses corresponding to the desired door position.
Blend Switch ± Dual Zone
The dual sliding Blend Switches have multiple
detents to control the full range of temperature that
the system can produce an any mode. The upper
slide pot controls the driver-side blend door, while
the lower slide pot controls the passenger-side
blend door. Sliding the switch results in the A/C ±
Heater Control Module signaling the actuator to
move the blend door. All door positions are deter-
mined relative to the number of commutator pulses
required to provide full travel of the door. On
command, the A/C ± Heater Control Module runs
the actuator for the number of pulses corresponding
to the desired door position.
Mode Switch
The single rotary Mode Switch has 13 detents to
either direct airflow to the panel outlets, a mix of
floor and panel outlets, floor outlets, a mix of floor
and defrost outlets, or defrost outlets. Rotating the
switch results in the A/C ± Heater Control Module
signaling the actuator to move the mode door. All
door positions are determined relative to the num-
ber of commutator pulses required to provide full
travel of the door. On command, the A/C ± Heater
Control Module runs the actuator for the number of
pulses corresponding to the desired door position.
18
GENERAL INFORMATION
Page 48 of 4284
3.9.2.11 HVAC DIAGNOSTICS
The A/C ± Heater Control Module is fully addres-
sable with the DRBIIIt. Two of the Control Mod-
ule's diagnostic capabilities that the DRBIIItwill
actuate include the A/C Cooldown Test to test A/C
system performance and the HVAC Door Recalibra-
tion Test to determine actuator travel span. After
performing either test, the Control Module will
display one or more messages on the DRBIIIt
screen. The message will indicate either that the
HVAC system passed the test or that there is a fault
currently active in the HVAC system. The DRBIIIt
can also extract active and stored Diagnostic Trou-
ble Codes (DTCs) from the control module. Active
DTCs are faults that currently exit in the HVAC
system. Active DTCs cannot be erased until the
condition causing the code is repaired. Stored DTCs
are faults that occurred in the HVAC system since
the control module received the last ªclear diagnos-
tic infoº message.
3.10 CABIN HEATER
NOTE: The Cabin Heater, also known as the
Diesel Cabin Heater Assist (DCHA), will be
referred to as the DCHA throughout most of
the General Information and the Diagnostic
Procedures in this manual.
3.10.1 GENERAL SAFETY INFORMATION
WARNING: DO NOT OPERATE THE DCHA IN
AN ENCLOSED AREA SUCH AS A GARAGE
THAT DOES NOT HAVE EXHAUST
VENTILATION FACILITIES. 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 PERFORMING A COM-
PONENT INSPECTION/REPAIR/REPLACE-
MENT. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
WARNING: ALWAYS DISCONNECT THE
VEHICLE'S BATTERY PRIOR TO PER-
FORMING ANY TYPE OF WORK ON THE
DCHA. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY OR DEATH.WARNING: NEVER ATTEMPT TO REPAIR THE
DCHA HEATER MODULE OR ANY OF ITS
INTERNAL COMPONENTS. ALWAYS PER-
FORM DCHA COMPONENT REPLACEMENT
IN ACCORDANCE WITH THE SERVICE
INFORMATION. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
CAUTION: Do not actuate the DCHA Field
Mode Test with the engine off. Failure to
follow these instructions may result in
internal damage to the DCHA Heater Module.
CAUTION: Always Perform The Cabin Heater
Pre-Test Prior To Performing Any Other Cabin
Heater Test For The Test Result To Be Valid.
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 Heater Module.
NOTE: Failure to prime the Dosing Pump
after draining the DCHA fuel line will prevent
DCHA heater activation during the first
attempt to start the heater. This will also set a
Diagnostic Trouble Code (DTC) in the DCHA
Control's memory. Do not perform the Dosing
Pump Priming Procedure if an attempt was
made to start the DCHA without priming the
Dosing Pump first. This will put excess fuel
in the DCHA Heater Module and cause smoke
to emit from the DCHA exhaust pipe when
heater activation occurs.
NOTE: Waxed fuel can obstruct the fuel line
and reduce flow. Check for the appropriate
winter grade fuel and replace as necessary.
3.10.2 COMPONENT DESCRIPTION AND
OPERATION
3.10.2.1 DCHA ASSEMBLY
The DCHA is a supplemental heater designed to
pre-heat the engine's coolant in order to supply the
vehicle's occupants with heat prior to the engine
reaching operating temperature. The DCHA assem-
bly mounts underneath the vehicle on the left side
floor pan near the front door opening. The DCHA
assembly connects to the vehicle's heater hoses and
has a fuel supply line that connects to the vehicle's
fuel tank.
19
GENERAL INFORMATION
Page 59 of 4284
WARNING: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL
COMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRBIIITSCREEN WHILE IN
MOTION. DO NOT HANG THE DRBIIITFROM
THE REAR VIEW MIRROR OR OPERATE IT
YOURSELF. HAVE AN ASSISTANT
AVAILABLE TO OPERATE THE DRBIIIT.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBIIIt(diagnostic read-out box)
Jumper wires
Ohmmeter
Voltmeter
Sentry Key Tester
Test Light
8310 Airbag System Load Tool
8443 SRS Airbag System Load Tool
Diagnostic Junction Port Tester 8339
6.0 GLOSSARY OF TERMS
ABSantilock brake system
ACMairbag control module
AECMairbag electronic control module
(ACM)
ASDMairbag system diagnostic module
(ACM)
AT Cautomatic temperature control
BCMbody control module
CABcontroller antilock brake
CMTCcompass/mini-trip computer
CPAconnector positive assurance
DABdriver airbag
DCHAdiesel cabin heater assist
(cabin heater)
DLCdata link connector
DTCdiagnostic trouble code
DRdriver
EBLelectric back lite (rear window de-
fogger)ECMEngine control module
EVICelectronic vehicle information center
FCMfront control module
GCCGulf Coast Countries
HVACheater ventilation, air conditioning
IPMintelligent power module
LDUlower drive unit
LHDLeft Hand Drive
MICmechanical instrument cluster
MTCmanual temperature control
MSMMmemory seat/mirror module
OBDon board diagnostics
ODOodometer
ORCoccupant restraint controller
PA Bpassenger airbag
PASSpassenger
PCIProgrammable Communication In-
terface (vehicle communication bus)
PCMpowertrain control module
PDCpower distribution center
PLGpower liftgate
PLGMpower liftgate module
PSDpower sliding door
PSDMpower sliding door module
PWMpulse width modulated
RHDRight Hand Drive
RKEremote keyless entry
SABseat airbag
SBTseat belt tensioner
SIACMside impact airbag control module
SKIMsentry key immobilizer module
SKISsentry key immobilizer system
SQUIBalso called initiator (located inside
airbag)
SRSsupplemental restraint system
TCMtransmission control module
VFDvacuum fluorescent display
VTSSvehicle theft security system
30
GENERAL INFORMATION
Page 362 of 4284
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
Page 426 of 4284
Symptom:
*NO RESPONSE FROM CABIN HEATER ASSIST - DIESEL ONLY
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE ECM
FUSED B+ CIRCUIT OPEN
GROUND CIRCUIT OPEN
SCI TRANSMIT CIRCUIT OPEN
CABIN HEATER ASSIST
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRB, attempt to communicate with the ECM.
Was the DRB able to I/D or communicate with the ECM?All
Ye s®Go To 2
No®Refer to the symptom list for problems related to no communica-
tion with the ECM.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
2 Turn the ignition off.
Disconnect the Cabin Heater Assist 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 3
No®Check the IPM Fuse #15 for an open. If open, check for a short to
ground on the Fused B+ circuit. If not open, repair the Fused B+
circuit for an open.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the Cabin Heater Assist C2 harness connector.
Measure the resistance between ground and the ground circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the ground circuit for an open.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the Cabin Heater Assist C1 harness connector.
Disconnect the DRB from the DLC.
Measure the resistance of the SCI Transmit circuit between the Cabin Heater Assist
connector and the DLC.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the SCI Transmit circuit for an open.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
397
COMMUNICATION
Page 427 of 4284
TEST ACTION APPLICABILITY
5 If there are no possible causes remaining, view repair. All
Repair
Replace the Cabin Heater Assist in accordance with the service
information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
398
COMMUNICATION
*NO RESPONSE FROM CABIN HEATER ASSIST - DIESEL ONLY Ð
Continued
Page 430 of 4284
Symptom:
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY
POSSIBLE CAUSES
ECM PCI NO RESPONSE
PCI BUS CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
NOTE: As soon as one or more module communicates with the DRB, answer
the question.
With the DRB, enter Body then Body Computer.
With the DRB, enter Anti-Lock Brakes.
With the DRB, enter Body then Electro/Mechanical Cluster (MIC).
With the DRB, enter Passive Restraints then Airbag.
Were you able to establish communications with any of the modules?All
Ye s®Go To 2
No®Refer to symptom PCI Bus Communication Failure in the Com-
munications category.
Perform ROAD TEST VERIFICATION - VER-2.
2 With the DRB read ECM Diagnostic Trouble Codes. This is to ensure power and
grounds to the ECM are operational.
NOTE: If the DRB will not read ECM DTC's, follow the NO RESPONSE TO
ECM (SCI only) symptom path, if vehicle will start. For NO START Condi-
tions follow the no start symptom in the Starting category.
Turn the ignition off.
Disconnect the ECM harness connectors.
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.
With the DRBIIItselect Pep Module Tools.
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 ground. Connect the Red lead to the PCI Bus circuit in the
ECM 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®Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No®Repair the PCI Bus circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
401
COMMUNICATION
Page 431 of 4284
Symptom:
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY
POSSIBLE CAUSES
CHECK ECM POWERS AND GROUNDS
CABIN HEATER ASSIST
SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE
SCI TRANSMIT CIRCUIT SHORTED TO GROUND
SCI TRANSMIT CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Perform the symptom Checking ECM Power and Ground Circuits in the Driveability
category.
Did the vehicle pass this test?All
Ye s®Go To 2
No®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
2 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance between ground and the SCI Transmit circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Go To 4
3 Turn the ignition off.
Disconnect the Cabin Heater Assist C1 harness connector.
Measure the resistance between ground and the SCI Transmit circuit.
Is the resistance below 5.0 ohms?All
Ye s®Repair the SCI Transmit circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No®Replace the Cabin Heater Assist in accordance with the service
information.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Disconnect the DRB from the DLC.
Disconnect the ECM harness connectors.
Disconnect the Cabin Heater Assist C1 harness connector.
Turn the ignition on.
Measure the voltage of the SCI Transmit circuit at the DLC connector (cav 7).
Is the voltage above 1.0 volt?All
Ye s®Repair the SCI Transmit circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No®Go To 5
402
COMMUNICATION
Page 432 of 4284
TEST ACTION APPLICABILITY
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance of the SCI Transmit circuit between the ECM connector and
the DLC.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the SCI Transmit circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
403
COMMUNICATION
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY ÐContinued