charging CHRYSLER VOYAGER 2001 Owner's Manual

TEST ACTION APPLICABILITY
6WARNING: 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, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
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 CHARGING VERIFICATION - VER-3.
No®Test Complete.
7 Turn the ignition off.
With a voltmeter, measure and record the voltage between the Battery terminals.
Disconnect the ECM harness connectors.
Turn the ignition on.
Measure the voltage of the Fuel Heater Relay Output circuit in the ECM C1 harness
connector.
Are the voltage measurements within 0.5 volt of each other?All
Ye s®Go To 8
No®Repair the Fuel Heater Relay Output circuit to the Engine
Control Module for high resistance.
Perform CHARGING VERIFICATION - VER-3.
8 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Generator Field harness connector.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ECM/PCM Relay
connector.
Turn the ignition on.
Measure the voltage of the Generator Field Driver circuit.
Is the voltage below 0.5 volt?All
Ye s®Go To 9
No®Repair the Generator Field Driver circuit for a short to voltage.
Perform CHARGING VERIFICATION - VER-3.
122
DRIVEABILITY - DIESEL
P0560-SYSTEM VOLTAGE TOO LOW ÐContinued

TEST ACTION APPLICABILITY
9 Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ECM/PCM Relay
connector.
Turn the ignition on.
Measure the voltage of the ECM/PCM Relay Output circuit in ECM harness
connector C1, cavities 4 and 5.
Is the voltage above 10.0 volts?All
Ye s®Go To 10
No®Repair the ECM/PCM Relay Output circuit for an open.
Perform CHARGING VERIFICATION - VER-3.
10 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Driver circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 11
No®Repair the Generator Field Driver circuit for an open.
Perform CHARGING VERIFICATION - VER-3.
11 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 CHARGING VERIFICATION - VER-3.
123
DRIVEABILITY - DIESEL
P0560-SYSTEM VOLTAGE TOO LOW ÐContinued

Symptom List:
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE
DEVIATION TOO HIGH
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE
DEVIATION TOO LOW
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE
TOO HIGH
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE
TOO LOW
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS
TOO LOW
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT
P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT
P0620-GENERATOR FIELD CONTROL MALF UNSTABLE CUR-
RENT
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0620-GENERATOR FIELD
CONTROL MALF BATTERY VOLTAGE DEVIATION TOO
HIGH.
When Monitored and Set Condition:
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH
When Monitored: With the engine running.
Set Condition: The ECM senses battery voltage above 16.5 volts.
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW
When Monitored: With the engine running.
Set Condition: The ECM senses battery voltage that is 1 or greater below target voltage.
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT
When Monitored: With the ignition on.
Set Condition: The ECM detects an open or short to ground on the Generator Field
Control circuit.
126
DRIVEABILITY - DIESEL

P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT
When Monitored: With the ignition on.
Set Condition: The ECM detects a short to voltage on the Generator Field Control circuit.
POSSIBLE CAUSES
INTERMITTENT CONDITION
GENERATOR FIELD
GENERATOR FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE
GENERATOR FIELD CONTROL CIRCUIT SHORTED TO GROUND
GENERATOR FIELD CONTROL CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRB, erase ECM DTCs.
Perform several ignition cycles, turning the ignition off for at least 10 seconds
between each ignition cycle.
Monitor the DRB for ECM DTCs.
Did this DTC reset?All
Ye s®Go To 2
No®Go To 7
2 Turn the ignition off.
Disconnect the Generator Field harness connector.
Measure the resistance of the Field Control terminals on the back of the Generator.
Is the resistance between 2 and 6 ohms?All
Ye s®Go To 3
No®Repair or replace the Generator as necessary.
Perform CHARGING VERIFICATION - VER-3.
3 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Generator Field harness connector.
Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 1 and cavity 4 of the ECM/PCM Relay
connector.
Turn the ignition on.
Measure the voltage of the Generator Field Control circuit.
Is the voltage below 0.5 volt?All
Ye s®Go To 4
No®Repair the Generator Field Control circuit for a short to voltage.
Perform CHARGING VERIFICATION - VER-3.
127
DRIVEABILITY - DIESEL
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVI-
ATION TOO HIGH Ð
Continued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect ECM harness connectors.
Disconnect the Generator Field harness connector.
Measure the resistance between ground and the Generator Field Control circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 5
No®Repair the Generator Field Control circuit for a short to ground.
Perform CHARGING VERIFICATION - VER-3.
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Control circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Generator Field Control circuit for an open.
Perform CHARGING VERIFICATION - VER-3.
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 CHARGING VERIFICATION - VER-3.
7WARNING: 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, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
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 CHARGING VERIFICATION - VER-3.
No®Test Complete.
128
DRIVEABILITY - DIESEL
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVI-
ATION TOO HIGH Ð
Continued

Verification Tests
CHARGING VERIFICATION - VER-3 APPLICABILITY
1. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
2. If the PCM has been replaced, perform step 3. Otherwise, continue with step 4.
3. If the vehicle is equipped with a factory theft alarm, start the engine at least 20 times in
order to be able to activate the alarm system when desired.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Start the engine.
6. Raise the engine speed to 2000 RPM for at least 30 seconds.
7. Allow the engine to idle.
8. Turn the ignition off for 20 seconds.
9. Turn the ignition on.
10. With the DRB, read ECM and PCM DTCs.
11. If this DTC has reset, or another DTC has set, look for any Technical Service Bulletins
(TSBs) that may relate to this condition. Return to the Symptom List if necessary.
12. If the charging system is functioning correctly and there are no DTCs, the repair is now
complete.
Are any DTCs or symptoms remaining?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
NO START VERIFICATION - VER-1 APPLICABILITY
1. NOTE: IMPORTANT! If the Engine Control Module, Sentry Key Immobilizer
Module or Powertrain Control Module have been replaced, ensure the programming
procedures for these modules have been performed in accordance with the Service
Information.
2. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Turn the ignition off for at least 10 seconds.
6. Attempt to start the engine.
7. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may
relate to this condition. Return to the Symptom List if necessary.
8. If the engine starts and continues to run, the repair is now complete.
Are any DTCs or symptoms remaining?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
223
VERIFICATION TESTS

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
International Symbols
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RSINTRODUCTION5
INTERNATIONAL SYMBOLS (Continued)

FASTENER USAGE
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL VEHICLE
CONTROL & DISPLAY
SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RGINTRODUCTION5a

Inspection and service should also be performed
anytime a malfunction is observed or suspected.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on any
suspension component, including the front suspen-
sion crossmember, the rear leaf springs, and the
rear axle. Do not hoist on the front and rear
bumpers, the lower liftgate crossmember, the lower
radiator crossmember, the down standing flanges
on the sill or the front engine mount.
FOR PROPER HOIST PLACEMENT REFER
TO (Fig. 8).
The hoisting points are identified by S.A.E.
inverted triangle hoisting symbols (Fig. 8). The front
hoisting points are at the bottom of the font rail
below the hoisting symbol approximately 250mm
behind the front suspension crossmember. When
using outboard lift hoists, verify that the hoist lift
pads have been properly adjusted to eliminate con-
tact between the hoist arm and the down standing
flange on the sill. The rear hoisting points are the
leaf spring front mounting brackets. The hoist pad
must be positioned to pick up the flanges on the
bracket, not the leaf spring.
When servicing the leaf springs or the leaf spring
mounting brackets, special provisions are required to
support the rear of the vehicle. Position the rear
hoist pads under the horizontal surface on the bot-
tom of the sill, inboard adjacent to the flange and
centered fore/aft between the jacking indicator tabs
on the lower flange.DO NOT HOIST ON THE
FLANGE.Place a soft pad between the hoist and the
painted surface on the sill to avoid scratching the fin-
ish.
JUMP STARTING
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
Fig. 8 HOISTING AND JACKING POINTS
1 - DRIVE ON LIFT
2 - FRAME CONTACT LIFT (SINGLE POST)
CHASSIS LIFT (NON-AXLE DUAL POST)
OUTBOARD LIFT (DUAL POST)
FLOOR JACK
3 - S.A.E. HOISTING SYMBOLS
0 - 16 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3)
On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accessories.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 8).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 minutes), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
Fig. 8 Jumper Cable Clamp Connections
1 - BATTERY POSITIVE CABLE
2 - POSITIVE JUMPER CABLE
3 - TEST INDICATOR
4 - BATTERY NEGATIVE CABLE
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
7 - ENGINE GROUND
0a - 8 LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESELRG